Download Cateye EC-3700 Service manual

Cateye Ergometer
Belt Drive, Automatic Type
Model EC-1200/EC-1600/EC-3600/EC-3700/EC-C400/EC-C400R
Service Manual
9.1.2002
Ver.01
Model
EC-1200
INDEX
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
•Repair & Adjustment Methods
1200 1600 3600 3700 C400 C400R
INTRODUCTION
•How to Use This Service Manual
•Name of Parts
1. Upright Type (w/o Flywheel) --------------------------------------------------------- 6~7
Upright Type (w/ Flywheel) ---------------------------------------------------------- 8~9
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ES-1:
Replacing the Wiring within the Frame --- 36~37
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ES-2:
Replacing the 5P Cable ---------------- 38~42
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ES-3:
Replacing the Power Supply Board ------- 43~44
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ES-4:
Correcting the Position
of Solenoid Coil --------------------------- 45~46
2. Recumbent Type (EC-3600, EC-3700 & EC-C400R) --------------------- 10~11
•Circuit Diagram ---------------------------------------------------------------------------------- 12
Part A
•Symptoms of Problems & Causes
T-1: No Display on Control Unit after Power ON --------------------------- 13~16
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ES-5:
Replacing the CDC Sensor ------------ 47~48
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ES-6:
Replacing the Panel Keyboard ------------ 49
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ES-7:
Replacing the Button Panel ---------------- 50
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ES-8:
Replacing the Printer ------------------------- 51
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ES-9:
Adjusting the Printing Darkness ----------- 52
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ES-10: Paper Jamming in Printer ------------------- 53
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ES-11: Replacing the Pulse Sensor Jack
and Pulse Sensor Jack Board -------- 54~55
T-2:
No Display of Cadence ------------------------------------------------------ 17~19
T-3:
No Display of Pulse Rate -------------------------------------------------------- 20
T-4:
No Printer Operation --------------------------------------------------------- 21~22
T-5:
No Loading --------------------------------------------------------------------- 23~26
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ES-12: Replacing the HR Receiving Board -- 56~57
T-6:
No Pedal Rotation (Locked) ---------------------------------------------------- 27
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MS-1:
T-7:
Unusual Noise
Replacing the Workload Unit
(w/o Flywheel) ---------------------------- 58~63
▲G
1. Continuous and Increasing. ---------------------------------------------- 28
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MS-2:
(w/ Flywheel) ---------------------------- 64~65
2. Periodical. --------------------------------------------------------------------- 29
3. Noise occurs when the pedal is rotated with a large loading. --- 30
Part B
•Removing the Frame Covers
D-1: Upright Type (EC-1200, EC-1600 & EC-C400) ---------------------------- 31
Recumbent Type (EC-3600, EC-3700 & EC-C400R) -------------------- 33
D-3:
Disassembly of a Control Unit -------------------------------------------------- 35
TitleNo
D-2:
Replacing the Workload Unit
▲G
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MS-3:
Adjusting the Flywheel ----------------------- 66
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MS-4:
Replacing the Timing Belt -------------- 67~68
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MS-5:
Replacing the Pulley 1-B -------------------- 69
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MS-6:
Replacing the Idler A Set -------------------- 70
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MS-7:
Replacing the Idler B Set ------------------- 71
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MS-8:
Replacing the Crank Pulley 1-A Set ------ 72~74
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MS-9:
Replacing the Cartridge BB Set ------ 75~76
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MS-10: Replacing the Post Spacer ----------------- 77
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MS-11: Adjusting the Spacer Spring --------------- 78
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MS-12: Replacing the Inner Pipe Spacer --------- 79
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MS-13: Replacing the Vertical Pipe Spacer ------ 80
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MS-14: Replacing the Leg Cover -------------------- 81
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MS-15: Replacing the Caster/Level Adjuster ----- 82
Cateye ergometer Service Manual
2
Model
EC-1200
EC-1600
1200 1600 3600 3700 C400 C400R
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MS-16: Replacing the Seat Post Knob ------------- 83
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MS-17: Replacing the Lock Pin ---------------------- 84
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MS-18: Replacing the Crank Cover ----------------- 85
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MS-19: Replacing the Center Cover
of Upright Type -------------------------------- 86
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MS-20: Replacing the Center Cover
of Recumbent Type --------------------------- 87
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MS-21: Replacing the Handlebar Grip ------------- 88
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MS-22: Replacing the Printer Cover ---------------- 89
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MS-23: Replacing the Paper Cutter ---------------- 90
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MS-24: Replacing the Handle Stem ---------------- 91
PART C
•List of Genuine Parts ----------------------------------------------------------------------- 92~103
Cateye ergometer Service Manual
3
EC-3600
EC-3700
EC-C400
EC-C400R
Model
EC-1200
How to Use This Service Manual
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Symbol marks used for safety precautions in this manual
The manual consists of Part A, Part B and Part C. Part A refers to trouble-shooting which
allows you to identify the cause and areas to be fixed depending on typical symptoms.
Part B shows how to repair and/or adjust specific defects. This part consists of repair
methods for electrical parts [ES] and those for mechanical parts [MS].
Part C lists up all genuine parts and corresponding part numbers that will be necessary
for replacement or stock
Whenever any problem has occurred on the main unit, take the following actions to repair
or adjust it.
1. Check and identify the cause by referring to Part A.
2. Identify the parts name by referring to Name of Parts.
3. Perform repair or adjustment in accordance with the instructions in Part B.
4. Replacement, if required, should be done by using genuine parts as specified in Part C.
Warning
Failure to observe this warning could result in serious injury or death.
Caution
Failure to observe this warning could result in physical injury or damage to the
machine.
Reference
This symbol mark denotes helpful information or associated items.
FOR SAFE OPERATION
<Electrical danger>
• During troubleshooting, checking the wiring, measuring voltage and electric current; be
careful to avoid electric shock.
• During maintenance, turn off the power unless it is required for maintenance.
<Mechanical danger>
• Be careful to avoid getting caught in rotation parts such as the gears, belts or rollers.
Familiarize yourself with the movements of these parts before using the equipment.
• It is possible that certain covers, moving parts, etc., may cause injury. Make sure to hold
covers, etc., securely during work.
<Important precautions>
• The machine is comprised of various parts, some of which are heavy. When moving or
removing such parts, be sure to hold these parts securely.
• When moving the machine, be sure that at least two persons work together.
Cateye ergometer Service Manual
4
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
R
Model
EC
EC
-12
00
ON
OF
F
Recumbent Type
Upright Type
Cateye ergometer Service Manual
5
-37
00
EC-C400R
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Name of Parts for Upright Type (w/o Flywheel)
Crank Pulley 1-A Set
Post Spacer
Cartridge BB Set
Lock Nut
Crank Cap
9 Adjust Screw
6 Spacer Spring
Post Spacer
Lock Nut
Frame
Adjust Screw
5 Spacer Spring
5P Cable
Seat Pipe
Cable Holder
Crank
Timing Belt
Idler B
Connector Cover
5P Cable Connector
CDC Magnet
CDC Sensor
Inlet Metal Base
Power Switch
Copper Plate
3 Idler Fixing Bolt [M6x16]
Frame
Idler Metal Base
Idler Spring B
Wiring within Frame
Leg Cover
Leg Pipe
3 Leg Pipe Fixing Screw
Caster
6
Levelling Knob
Power Supply
Board
Power Supply Board
Fixing Screw
[Tapping Screw(2)
4x12c]
780-7050
Workload Unit
Plastic Pulley
Solenoid Coil
Mounting Base
Solenoid Coil
7 SW Nut M6
Cateye ergometer Service Manual
6
Levelling Knob
3 Workload Unit Mounting Base
[Screw Set (+) (M6x16)]
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Handlebar Post
Cable Holder
Center Cover
780-6990 Crank Pulley 1-A Set
Seat Post
780-7000 Pulley Flange
Frame Cover
Crank Cover
4 Crank Cover Fixing Screw
Inlet Metal Base
AC Adapter Inlet
724-1021 Timing Belt
9 Crank Bolt
2 Workload Unit Reinforcing Metal Base Nut
Power Supply Board
Workload Unit Reinforcing Metal Base
1 Workload Unit Reinforcing
Metal Base Fixing Nut
Leg Pipe Fixing Screw
Leg Pipe
Lever Cover
3 Screw Set(+) (M6x16)
3 Workload Unit
Fixing Bolt
Hexagon Head U Nut
Levelling Knob 780-7010 Pulley 1-B
Solenoid Coil
Idler A Mounting Bolt
780-7030 Idler A
780-7040 Idler Spring A
Cateye ergometer Service Manual
7
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Name of Parts for Upright Type (w/ Flywheel)
5P Cable
Post Spacer
Lock Nut
5P Cable Connector
780-6990 Crank Pulley 1-A Set
Cartridge BB Set
Crank Cap
Adjust Screw
Post Spacer
Lock Nut
Adjust Screw [M8x10]
5 Spacer Spring
Seat Pipe
Flywheel Mounting Metal Base
Cable Holder
Flywheel Metal
7 Flywheel Fixing Screw [SW Nut (M6)]
3 Flywheel Metal Base Fixing Screw
Crank
[Screw Set (+) (M6x16)]
Timing Belt
Idler B
Inlet Metal Base
Power Switch
CDC Magnet
CDC Sensor
Copper Plate
3 Idler Mounting Bolt [M6x16]
Frame
Idler Metal Base
Idler Spring B
Wiring within Frame
Leg Pipe
3 Leg Pipe Fixing Screw
Leg Pipe
Levelling Knob
Workload Unit
7 SW Nut (M6)
Caster
Power Supply Board
6 Power Supply Board
Plastic Pulley
Solenoid Coil
Mounting Base
Fixing Screw
[Tapping Screw (2) 4x12c] Solenoid Coil
3 Workload Unit Mounting Bolt
[(M6x16)]
Cateye ergometer Service Manual
8
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
780-6990 Crank Pulley 1-A Set
780-7000 Pulley Flange
Plain Belt
EC-C400R
Seat Post
Handlebar Post Cover
(EC-1600 only)
Center Cover
Flywheel
Frame Cover
Crank Cover
1 Workload Unit Reinforcing
Metal Base fixing Nut (M8-3)
Power Supply
Board
2 Flywheel Fixing Screw
Flywheel Metal Base
3 Flywheel Metal Base Fixing Screw
Inlet Metal Base
AC Adapter Inlet
4 Crank Cover Fixing Screw
Crank Bolt
724-1021 Timing Belt
2 Workload Unit Reinforcing
Metal Base Nut [Hexagon Nut (M6-3)]
Workload Unit
Reinforcing Metal Base
780-7050 Workload Unit
Leg Pipe
Lever Cover
3 Workload Unit
Levelling Knob
Mounting Bolt
(M6x16)
Hexagon Head U Nut
780-7010 Pulley 1-B
3 Screw Set(+) (M6x16)
Solenoid Coil
Idler Mounting Bolt
Idler A
Idler Spring A
Cateye ergometer Service Manual
9
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Name of Parts for Recumbent Type (EC-3600, EC3700 & EC-C400R)
6 Power Supply
Board Fixing Bolt
Crank
Crank Bolt
5P Cable Connector
Power Supply
Board
5P Cable Set
Cable Holder
Wiring within Frame
Frame
Cartridge BB Set
3 Flywheel Metal Base Fixing Screw
CDC Sensor
Timing Belt
Flywheel
Copper Plate
7 Flywheel Fixing Screw
Idler B
Flywheel Metal Base
3 Idler Fixing Bolt
Plain Belt
Idler Spring B
Idler Metal Base
Solenoid Coil
Mounting Base
Frame Cover
3 Workload Unit Mounting
Solenoid Coil
Center Cover
Crank Cover
Rear Support Pipe
Workload Unit
Leg Pipe Fixing Screw
Seat Pipe
4 Crank Cover Fixing Screw
Base [Screw Set (+) (M6x16)]
Plastic Pulley
Inner Pipe
Cateye ergometer Service Manual
10
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
780-6990 Crank Pulley 1-A Set
780-7000 Pulley Flange
Power Supply Board
Cable Holder
CDC Magnet
724-1022 Timing Belt
Crank Cap
Cable Holder
Flywheel
Plain Belt
7 Flywheel Fixing Screw
Idler A Mounting Bolt
2 Workload Unit Reinforcing
Metal Base Nut
Workload Unit
Reinforcing Metal Base
781-5581 Workload Unit
3 Flywheel Metal Base Fixing Screw
780-7040 Idler Spring A
Solenoid Coil
ON
3 Workload Unit Mounting Base
[Screw Set (+) (M6x16)]
780-7010 Pulley 1-B
Inlet Metal Base
OFF
780-7030
Idler A
Hexagon Head U Nut
AC Adapter Inlet
Power Switch
Front Leg with Casters
Caster
Cateye ergometer Service Manual
11
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Circuit Diagram for Automatic Type Cateye Ergometer
Wiring within Frame
AC Adapter
100V AC
CN4 (Connector 4)
Black Cable (-)
12V DC❈
-
AC Plug
❈Fluctuate depending on the electric load
DC Connector
AC Adapter Inlet
Switch
Red Cable (+)
+
About 16V when the load is zero.
DC Power Supply
CN4
Power Supply Board
+ -
(Connector 4)
Cadence Sensor
CN3
Magnet
C2
+
C1+
❈❈
5P Cable to Control Unit
R2
CN2
R8
Common Line
Cadence Signal
REG
R3
Control Unit Power Supply
VR1
R7
TR2
Solenoid Coil Current Control Signal
IC1
TR1
Printer Power Supply (+5V)
R1
Solenoid Coil Current Control Circuit
Power Supply Control Circuit
for Printer
CN1
D1
Metal Pulley
Timing Belt
Plastic Pulley
Timing
Belt
Coil
Workload Unit
Cadence Sensor
❈❈
Crank Pulley 1-A Set
Pedal
Electromagnet
Copper Disk Plate
Pulley 1-B
Magnet
Crank
Cateye ergometer Service Manual
12
Model
T-1
EC-1200
EC-1600
EC-3600
No Display on Control Unit after Power ON. (1)
Check
Maintenance
Illsutrations
Check the power is available at the wall socket
before proceeding to checking of causes.
Normal for 14V thru 19V
[1] Checking the AC Adapter
DC Connector
1. Detach the plug of AC adapter from the AC
adapter inlet of the main unit.
Red Cable
2. Connect the wall socket plug of the AC adapter
to the wall socket.
Black Cable
3. Using a tester, measure the voltage at the plug
which will be connected to the main unit. (Fig. 1)
Fig. 1
● The AC adapter will be working fine, if the
voltage is minus (-) at the inner area and
plus (+) at the outer area of the connector
and also the meter reading is in the range
of 14V to 19V.
● When the measured voltage is 0V, or less
than 14V, the AC adapter will be defective.
Caution
EC-3700
Replace the AC adapter.
Never short-circuit the plug of AC
adapter. This will damage the AC
adapter.
If the AC adapter is working normally, the system
checks the items on the next page.
Cateye ergometer Service Manual
13
EC-C400
EC-C400R
Model
T-1
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
No Display on Control Unit after Power ON. (2)
Check
Maintenance
Illustrations
[2] Checking the Wiring within the Frame
Normal for 14V thru 19V
1. When the AC adapter is found to be correct,
proceed to checking of wiring within the frame.
Loosen the four screws on the handlebar stem
to remove the control unit. (Fig. 2)
5P Cable
Black Cable
Terminal 3
(+)
Cable Connector
2. Remove the 5P cable which is connected to the
back of the control unit. (Fig. 2)
3. Connect the AC adapter, and turn on the main
unit.
4. Using a tester, measure the voltage across the
terminals 1 (-) and 3 (+) of the 5P cable. (Fig. 3)
Terminal 1 (-)
Fig. 2
Replace the control unit.
● The main unit side will be working fine if the
meter reading is in the range of 14V to 19V.
This means the control unit will be defective.
Cateye ergometer Service Manual
14
Red Cable
Fig. 3
Model
T-1
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
No Display on Control Unit after Power ON. (3)
Check
Maintenance
Illsutrations
[3] When the meter reading at step 2. is 0V or less
than 14V, check the main unit in accordance with
the following procedures:
Correct for 14V thru 19V
1. Remove the frame cover. (See sections D-1
and D-2 "Removing the Frame Covers.")
Power Supply Board
2. With the control unit removed, connect the AC
adapter, and turn on the power switch. Measure
the voltage across the electrolytic capacitor C1
on the power supply board (25V 1000µV).
(Fig. 4)
Caution
Black Cable
The layout of the power supply
board may be different from lot to
lot. (Figs. 5 and 6)
● The wiring within the frame is correct when
the measured voltage is in the range of 14V
to 19V. When the voltage across the
electrolytic capacitor on the power supply
board is correct, the 5P cable, which
connects the power supply board and the
control unit, may be defective.
Replace the 5P cable.
● When the measured voltage is 0V, the
wiring within the frame is defective.
Replace the Inlet Metal Base Set.
● When the problem cannot be remedied
even if the 5P cable is replaced, the power
supply board may be defective.
Replace the power supply board.
Reference
Red Cable
See the Section ES-2
"Replacing the Frame."
Fig. 4
Power Supply Board A
Reference
Reference
Power Supply Board B
See the Section ES-1
"Replacing the Wiring
within the Frame."
See the Section ES-3
"Replacing the Power
Supply Board."
Fig. 5
Cateye ergometer Service Manual
15
Fig. 6
Model
T-1
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
No Display on Control Unit after Power ON. (4)
Check
Maintenance
Illustrations
<MAJOR DEFECTS>
Back Light
• Back light does not work. (The power is on, but
the back light does not work) (Only for ECC400 and C400R)
● The control unit is defective.
Replace the control unit with a brand
new one.
1
1
2
2
3
3
1
1
2
2
3
3
LED
• Push-button operation does not work.
● The control unit is defective.
Replace the control unit with a brand
new one.
• Cannot read data card.
Check that the card has been inserted correctly
and the procedure has been carried out
correctly.
Reference
Fig. 1
See the Operation Manual.
● If the card has been inserted correctly, this
indicates that the control unit is defective.
Replace the control unit with a brand
new one.
• LED on the control unit does not light. (Only for
EC400 and EC-C400R)
● The control unit is defective.
Replace the control unit with a brand
new one.
Cateye ergometer Service Manual
16
Fig. 1
Model
T-2
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
No Display of Cadence (The cadence remains at zero (0) and does not count when the pedal is rotated.) (1)
Check
Maintenance
Illsutrations
[1] Checking the Control Unit
The case of no short-circuiting
1. Turn off the power. Loosen the four screws on
the handlebar stem to remove the control unit.
Black Cable
2. Remove the cable connector which is connected to the back of control unit.
In case a short-circuiting is
found. One zero (0) is
detected during one rotation
of the pedal.
3. Slowly rotate the pedal while measuring the
resistance across the connector terminals 1
and 2 of the 5P cable. (Fig. 1)
● When there is one short-circuiting (resistance becomes zero) during one rotation of
the pedal, the control unit is defective.
2
5
Terminal 2
Red Cable
5P Cable
Fig. 1
Cateye ergometer Service Manual
17
4
1
Replace the control unit with a brand
new one.
When there is no short-circuiting, proceed to the
following check procedures.
3
Terminal 1
Model
T-2
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400R
No Display of Cadence (The cadence remains at zero (0) and does not count when the pedal is rotated.) (2)
Maintenance
Check
Illustrations
[2] Checking the Main Unit
Power Supply Board
1. Remove the frame cover. (See the Section D-1
and D-2 "Removing the Frame Covers.")
2. Remove the CN-3 connector on the power
supply board. (Fig. 2)
3. Slowly rotate the pedal while checking
shortcircuit across the two terminals of the CN3 connector by using a tester to see if there is
one short-circuiting during one rotation of the
pedal. (Fig. 3)
Caution
EC-C400
Fig. 2
The case of no
short-circuiting
When the pedal is rotating, keep
hands away from the workload unit.
● If short-circuiting is found, the 5P cable
which connects the power supply board and
the control unit is defective.
Replace the 5P cable.
Reference
See the Section ES-2
"Replacing the 5P Cable."
Black Cable
In case a shortcircuiting is found.
One zero (0) is
detected during one
rotation of the pedal.
Red Cable
When there is no short-circuiting, proceed to the
following check procedures.
CN-3 Connector
Fig. 3
Cateye ergometer Service Manual
18
Model
T-2
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
No Display of Cadence (The cadence remains at zero (0) and does not count when the pedal is rotated.) (3)
Check
Maintenance
Illsutrations
[3] Check the positional relation between the CDC
sensor and the magnet of the large gear. (Fig. 4)
CDC Sensor
1. Secure a gap of about 2 mm between the
surface of the CDC sensor and that of the CDC
magnet. (Fig. 5)
Approx.
2 mm
Check if there is any short-circuiting in the CN3 connector again.
● When a short-circuiting is found, the
positional relation between the CDC sensor
and the CDC magnet of the large gear is
incorrect.
● When there is no shortcircuit, the CDC
sensor is defective.
Pulley 1-A
Magnet
Fig. 4
Replace the CDC sensor.
Reference
See the Section ES-5
"Replacing the CDC
Sensor".
Cateye ergometer Service Manual
19
Model
T-3
EC-1200
EC-1600
EC-3600
EC-3700
No Display of Pulse Rate
Maintenance
Check
Illustrations
1. Turn on the power to display the in-training
screen (any exercise program).
2. Install a brand new pulse sensor, and check if
pulse rate will be displayed.
● When the pulse rate can be displayed, the
pulse sensor is defective.
Replace the pulse sensor with a brand
new one.
● If the pulse rate cannot be displayed, this
indicates that the pulse sensor jack or pulse
sensor jack board is defective.
Replace the pulse sensor jack or
pulse sensor jack board with the
brand new one.
Reference
See the Section ES-11
"Replacing the Pulse
Sensor Jack and Pulse
Sensor Jack Board."
Cateye ergometer Service Manual
20
EC-C400
EC-C400R
Model
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
No Printer Operation (1)
In such cases as display of the LCD panel, etc.
operate without problem, but the printer does not
operate, the following cases are possible:
[1] Checking the Control Unit
1. Check that the printer symbol is displayed on
the LCD panel and the printer is in a working
status. (Fig. 1)
2. Check if the setting of control unit is in the
setting that the printer is not used. (Check if
the No.4 select switch on the back of the
control unit is in the "OFF" position.) (Fig. 2)
ON
Printer Symbol
In case the printer symbol is not
indicated on the LCD panel, press the
printer button to have the symbol
indicated.
1
Tweezer
Printer Cover
● Remove the thermal paper if it is jammed.
(Fig. 3)
Paper Cutter
Fig. 3
5. With the new control unit installed, check the
printer operation.
Replace the control unit with a brand
new one.
When the printer does not operate after the abovestated checks, proceed to the following procedures:
Cateye ergometer Service Manual
21
3 4
OFF
Select Switch
Control Unit
4. When no other problems are found, replace
the control unit with a brand new one.
2
TIME
Fig. 1
3 Check if the thermal paper is not jammed at
the printer head.
● When the printer works fine, the control unit
is defective.
1 2 3 4
Illsutrations
ON MD
Maintenance
OFF
Check
ON
T-4
EC-1200
Back of Control Unit
Fig. 2
Model
T-4
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
No Printer Operation (2)
Maintenance
Check
Illustrations
[2] Checking the Main Unit
Power Supply Board
1. Turn off the power, and loosen the four screws
on the handlebar stem to remove the control
unit. (Fig. 4)
2. Remove the cable connector which is connected to the back of the control unit. (Fig. 4)
Cable Connector
3. Remove the frame cover. (See the Section D1
& D2 "Removing the Frame Covers.")
4. Remove the CN-2 connector on the power
supply board. (Fig. 5)
Fig. 4
5. Using a tester, check for any short-circuiting
across Terminal 1s and Terminal 5s at both
ends of the 5P cable which connects the power
supply board and the control unit. (Fig. 6)
Fig. 5
Normal when zero (0)
● When there is no shortcircuit, the 5P cable
is disconnected.
Replace the 5P cable.
● When it is short-circuited, the power supply
board is defective.
Replace the power supply board.
Reference
Reference
See the Section ES-2
"Replacing the 5P Cable."
Connector
Terminal 5
See the Section ES-3
"Replacing the Power
Supply Board."
5P Cable
Fig. 6
Cateye ergometer Service Manual
22
Connector Terminal 5
Model
T-5
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
No Loading (Check of mechanical systems)
Check
Maintenance
Illsutrations
[1] Checking the Mechanical Systems
See the Section D1 & D2 "Removing the Frame
Covers" to remove the frame cover, and check the
inside of frame.
1. Check if the timing belt has not been cut.
(Fig. 1)
● The timing belt is cut.
2. Rotate the crank and check if the belt of the
workload unit will rotate. (Fig. 2)
Caution
When the crank is rotating, keep
hands away from the workload
unit.
Timing Belt
Replace the timing belt with a brand
new one.
Reference
See the Section MS-4
"Replacing the Timing
Belt."
Replace the pulley 1-B with a brand
new one.
Reference
See the Section MS-5
"Replacing the Pulley 1-B
Set."
● The pulley 1-B set is idling.
Pulley 1-B
Idler A
Crank Pulley 1-A Set
3. Check if the belt (timing belt) of the workload
unit has not been cut. (Fig. 2)
● The workload unit timing belt is cut.
4. Check if the plastic pulley of the workload unit
has not been broken. (Fig. 2)
● The plastic pulley is broken.
Replace the workload unit.
See the Sections MS-1 &
MS-2 "Replacing the
Workload Unit."
Replace the workload unit.
Reference
Reference
Fig. 1
Workload Unit
Timing Belt
See the Sections MS-1 &
MS-2 "Replacing the
Workload Unit."
Plastic Pulley
Fig. 2
Cateye ergometer Service Manual
23
Pulley 1-B
EC-C400R
Model
T-5
EC-1200
EC-1600
EC-3700
No Loading (Check of Electrical Systems) (1)
Check
Maintenance
Illustrations
[2] Checking the Electrical Systems
1. Connect the AC adapter, and turn on the power
of the main unit.
2. Select the manual training program, set the
pedal torque setting to 4.0 kg·m, and rotate the
pedal at the rate of 50 rpm. If you can rotate it
quite easily, no load will be applied.
Caution
EC-3600
When the pedal is rotating, keep
hands away from the workload unit.
3. Replace the control unit with a brand new one.
4. Again, check the torque status under the
manual training program.
● When the pedal torque is loaded, the
control unit is defective.
Replace the control unit with a brand
new one.
When no torque loading is possible, proceed to the
following procedures.
Cateye ergometer Service Manual
24
EC-C400
EC-C400R
Model
T-5
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
No Loading (Check of Electrical Systems) (2)
Check
Maintenance
Illsutrations
1. Turn off the power, and loosen the four screws
on the handlebar stem to remove the control
unit. (Fig. 1)
Power Supply Board
2. Remove the cable connector which is connected to the back of the control unit. (Fig. 1)
3. Remove the frame cover.
Reference
See the Sections D1 & D2 "Removing the Frame Covers."
CN-2 Connector
4. Remove the CN-2 connector on the power
supply board. (Fig. 2)
Fig. 1
5. Using a tester, check for any short-circuiting
across Terminal 1s and Terminal 4s at both
ends of the 5P cable which connects the power
supply board and the control unit. (Fig. 3)
● When there is no shortcircuit, the 5P cable
is disconnected.
When it is short-circuited, proceed to the following
procedures:
Fig. 2
Normal when zero (0)
Replace the 5P cable with a brand
new one.
Reference
See the Section ES-2 "
Replacing the 5P Cable."
Connector
Terminal 4
5P Cable
Fig. 3
Cateye ergometer Service Manual
25
Connector
Terminal 4
Model
T-5
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
No Loading (Check of Electrical Systems) (3)
Maintenance
Check
Illustrations
1. Remove the connector CN-1 from the power
supply board, and measure the resistance
across Terminals 2 and 3 of the connector.
When the reading is in the range of 9Ω to 14Ω,
the connector is all right. (Figs. 4 & 5)
● When the meter reading is exceedingly
large, the solenoid coil is defective.
● When the meter reading is in the acceptable range, the power supply board may be
defective.
Normal for 14V thru 19V
Replace the workload unit.
Reference
See the Sections MS-1 &
MS-2 "Replacing the
Workload Unit."
Replace the power supply board.
Reference
Connector
Terminal 2
CN-1 Connector
Fig. 4
Connector
Terminal 3
See the Section ES-3
"Replacing the Power
Supply Board."
CN-1 Connector
Fig. 5
Cateye ergometer Service Manual
26
To Solenoid
Coil
Model
T-6
EC-1200
EC-1600
EC-3600
EC-3700
No Pedal Rotation (Locked)
Check
Maintenance
Illsutrations
1. Remove the frame cover, and check the inside
of frame.
Reference
See the Sections D1 & D2 "Removing the Frame Covers."
2. Check if the plain belt of the flywheel has not
been detached. (Fig. 1)
● No damage on the plain belt
Apply the plain belt correctly.
Reference
● The plain belt is damaged.
See the Section MS-2
"Replacing the Workload
Unit (w/ Flywheel)."
Replace the workload unit and free
wheel with brand new ones.
Reference
See the Section MS-2
"Replacing the Workload
Unit (w/ Flywheel)."
Plain Belt
Fig. 1
Cateye ergometer Service Manual
27
EC-C400
EC-C400R
Model
T-7-1
EC-1200
EC-1600
EC-3600
EC-3700
Unusual Noise (Continuous and Increasing)
Maintenance
Check
Illustrations
The noise generating source will be different depending on the cases whether it is of continuous noise or
periodical noise (several times per rotation of pedal).
Timing Belt
[1] Noise is continuous and increasing.
1. Remove the frame cover. (See the Sections D1 & D-2 "Removing the Frame Covers.")
2. Check if the idler A has been worn out. (Fig. 1)
When it has been worn out, replace it
with a brand new idler A set.
Reference
3. Check if the idler B has been worn out. (Fig. 2)
When it has been worn out, replace it
with a brand new idler B set.
Reference
4. Check if the plain belt has been deviated in
position, thus causing friction.
See the Section MS-6
"Replacing the Idler A Set."
See the Section MS-7
"Replacing the Idler B Set."
When the plain belt is shifted and is
going to be damaged, replace both
the workload unit and the flywheel set
with new ones.
Idler A
Fig. 1
Idler Set
Idler B
Plain Belt
Timing Belt
Plastic Pulley
Fig. 2
Cateye ergometer Service Manual
28
Fig. 3
EC-C400
EC-C400R
Model
T-7-2
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Unusual Noise (Periodical)
Check
Maintenance
Illsutrations
[2] Noise is Periodical.
Crank
1. Noise occurs around once per rotation of the
pedal.
● The pedal installation may not be correct.
(Fig. 1)
Use a No.15 wrench and securely
fasten the pedal to the crank. (both
sides)
No.15 Wrench
2. Sliding noise occurs around 17 times per
rotation of the pedal.
Pedal
Solenoid Coil
Remove the frame cover, and check the inside of
frame.
Reference
Fig. 1
See the Sections D-1 & D-2
"Removing the Frame Covers."
● The copper disc plate of the workload unit
may touch the solenoid coil. (Figs. 2 & 3)
Core Slit
Fig. 2
Copper Disc Plate
Core Slit
Copper Disc Plate
Core
Core
Correct the position of the copper disc
plate.
Reference
See the Sections ES-4
"Correcting the Position
of Solenoid Coil."
[If the plate is warped and the position
of solenoid coil cannot be corrected,
replace the workload unit.]
Reference
Solenoid Coil
❍ Correct Position
Fig. 3
See the Sections MS-1 &
MS-2 "Replacing the
Workload Unit."
Cateye ergometer Service Manual
29
✕ Copper disc plate
Solenoid Coil
is in contact with the core.
Fig. 4
Model
T-7-3
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Unusual Noise (Noise occurs when the pedal is rotated with a large torque.)
Maintenance
Check
Illustrations
[3] Noise occurs when the pedal is rotated with a
large torque.
Idler B
A large sound "bang" occurs when the pedal is
abruptly rotated with a large torque.
Pawl
Remove the frame cover, and check the inside of
frame.
Reference
See the Sections D-1 & D-2
"Removing the Frame Covers."
1. Check if the idler spring B is detached.
Hook the idler spring B on the pawl of
the idler.
Caution
2. Check if the idler mounting bolt is detached or
loosened.
Idler
Mounting Bolt
Idler Spring B
Be careful that the end of
the spring does not cause
injury to your hands.
Idler Metal Base
Fig. 1
Securely fasten the idler mounting bolt.
Cateye ergometer Service Manual
30
Model
D-1
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Removing the Frame Covers (1)
Upright Type (EC-1200, EC-1600 & EC-C400)
Crank
When any repair or adjustment of parts within the
frame is required, remove the frame covers in the
following procedures.
No.15 Wrench
REMOVAL
1. Remove the pedals at both the left and right
sides. (The left side pedal can be removed by
turning it in the clockwise direction, and the
right side pedal can be removed in the counterclockwise direction.) (Fig. 1)
2. Remove the crank cover fixing screws. The
narrow-width area of the crank cover should be
positioned in between the frame cover and the
crank. (Fig. 2)
ON
OFF
Pedal
Crank Cover
Fig. 1
Fig. 2
Lift upward.
Leg Pipe Fixing Screw
ON
OF
F
3. Remove the leg pipe fixing screws. (Fig. 3)
* You do not have to remove the leg pipe itself.
* For the model EC-1600, remove the leg pipe
cover.
Front
Center
Cover
Rear
Leg Pipe Fixing Screw
4. Shift the rubber base at the seat post lock knob
away from the center cover.
5. Loosen the center cover fixing screw a little,
and lift the center cover upward. (Do not
remove it.) (Fig. 4)
Fig. 3
Fig. 4
Frame Cover
ON
6. Loosen the four screws on the inlet cover. (Fig. 5)
OF
Four (4)
Screws
F
7. Remove the frame cover fixing screw with a
screwdriver before removing the frame cover.
(Fig. 6)
Inlet Cover
TitleNo
Center Cover Fixing Screw
Fig. 5
Fig. 5
Cateye ergometer Service Manual
31
Model
D-1
EC-1200
EC-1600
Removing the Frame Covers (2)
ASSEMBLING
1. Place the frame covers onto the frame at both
right and left sides, paying attention to the
position of the crank.
2. Fix the right and left frame covers with frame
cover fixing screws.
3. Mount the inlet cover with four screws. (Fig. 5)
4. Set the center cover to the frame cover correctly in position, and fix it with the center cover
fixing screws. (Fig. 4)
5. Pass the crank through the hole on the crank
cover, and fix the crank cover onto the frame
cover with screws. (Fig. 2)
6. Set the rubber base for the seat post lock knob,
and then mount the right and left pedals.
7. Fix the leg pipe with the leg pipe fixing screws.
(For the model EC-1600, mount the leg pipe
cover.)
Cateye ergometer Service Manual
32
EC-3600
EC-3700
EC-C400
EC-C400R
Model
D-2
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Removing the Frame Covers (1)
Recumbent Type (EC-3600, EC-3700 & EC-C400R)
When any repair or adjustment of parts within the
frame is required, remove the frame covers in the
following procedures.
Crank
■REMOVAL
No.15 Wrench
1. Remove the pedals at both the left and right
sides. (The left side pedal can be removed by
turning it in the clockwise direction, and the
right side pedal can be removed in the counterclockwise direction.) (Fig. 1)
2. Remove the crank cover fixing screws. The
narrow-width area of the crank cover should be
positioned in between the frame cover and the
crank. (Fig. 2)
Leg Pipe
Fixing Screw
Pedal
Crank Cover
Fig. 1
Fig. 2
Frame Cover
Center Cover
3. Remove the leg pipe fixing screws. (Fig. 3)
* You do not have to remove the leg pipe itself.
R
4. Remove the frame cover fixing screw with a
screwdriver before removing the frame cover.
(Fig. 4)
Screw
Fig. 4
Cateye ergometer Service Manual
33
Front Leg
with Casters
Fig. 3
Model
D-2
EC-1200
EC-1600
Removing the Frame Covers (2)
■ASSEMBLING
1. Place the frame covers onto the frame at both
right and left sides, paying attention to the
position of the crank. At the same time, the
center cover should be built in.
2. Fix the right and left frame covers with frame
cover fixing screws.
3. Pass the crank through the hole on the crank
cover, and fix the crank cover onto the frame
cover with screws. (Fig. 2)
4. Fix the front leg with casters with the leg pipe
fixing screws.
5. Mount the pedals.
Cateye ergometer Service Manual
34
EC-3600
EC-3700
EC-C400
EC-C400R
Model
D-3
EC-1200
EC-3600
EC-3700
EC-C400
EC-C400R
Disassembly of a Control Unit
1. Turn off the power and remove the control unit,
loosening the four screws before doing so.
Remove the cable connector from the control
unit, too. (Fig.1)
Reference
EC-1600
Control Unit
Cable
Connector
See the operation manual for details
relating to each model.
2. Turn over the control unit to remove the six to
eight screws on the back side. This can be
separated to the upper and lower body.
As the upper and lower bodies are connected
with cables, open the unit slowly.
5P Cable
Screws
Screws
EC-3600 3700 C400R
EC-1200 1600 C400
Fig. 1
Screws
Screws
Screws
EC-1200 3600
EC-1600 3700
Fig. 2
Cateye ergometer Service Manual
35
EC-C400 C400R
Model
ES-1
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the Wiring within the Frame (1)
[A] Removing the Wiring Parts
1. Remove the frame cover.
Reference
Power Supply
Board
Inlet Metal Base
Power Supply
Board
See the Sections D-1 & D-2
"Removing the Frame Covers."
2. Loosen the two screws on the inlet metal base
to remove them. (Fig. 1)
3. With the stopper being held with fingers, pull
the CN-4 connector off the power supply
board. (Fig. 2)
ON
4. Cut the cable holder (two places) with a
nipper. (Fig. 3)
OFF
EC-1200 & EC-1600 C400
EC-3600 & 3700 C400R
Inlet Metal Base (for Upright Type)
Inlet Metal Base (for Recumbent Type)
ON
Screws
DC Jack
OFF
ON
DC Jack
Screws
OFF
Fig. 1
Power Supply Board
Hold the stopper.
Cable Holders
Fig. 2
Fig. 3
Cateye ergometer Service Manual
36
Inlet Metal Base
Model
ES-1
EC-1200
EC-1600
Replacing the Wiring within the Frame (2)
[B] Mounting the Brand New Wiring Parts
1. Mount the brand new inlet metal base to the
frame with two screws.
2. Pass the wiring cable from beneath the DC jack
of the power supply board along with the
square pipe (21mm x 21mm) to the left direction, and then pass it through the back of the
inlet metal base along with the square pipe
toward the switch.
3. Connect the CN-4 connector to the power
supply board.
4. Refer to the Section (2) "Checking the Wiring
within the Frame" of T-1 "No Display on the
Control Unit after Power ON" (1) , measure the
voltage across the electrolytic capacitor C-1 to
check that it is in the correct range of 14V to
19V.
5. Use the two cable holders to fix the CDC
sensor cable together with the solenoid coil
cable. (Fig. 3)
6. Provisionally connect the control unit, and
check the unit works fine after turning on the
power. Then, completely assemble the frame
cover.
Cateye ergometer Service Manual
37
EC-3600
EC-3700
EC-C400
EC-C400R
Model
ES-2
EC-1200
EC-1600
EC-3600
Replacing the 5P Cable : For the model EC-1200 and EC-C400 (1)
● Removing the Existing Cable
EC-1200
1. Loosen the four screws which fix the control
unit to remove the control unit. Also, remove
the cable connector. (Fig. 1)
2. Remove the cable holder which fixes the 5P
cable to the handlebar post.
Power Supply Board
Cble
Connector
3. Remove the frame cover.
Reference
See the Section D-1 "Removing
the Frame Covers."
Screws
Fig. 1
Fig. 2
4. Remove the CN-2 connector from the power
supply board. (Fig. 2)
5. Cut the cable holders which fix the 5P cable to
the frame, and remove the 5P cable.
Cateye ergometer Service Manual
38
EC-3700
EC-C400
EC-C400R
Model
ES-2
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the 5P Cable : For the model EC-1200 & EC-C400 (2)
● Mounting the Brand New Cable
1. Mark the 5P cable at a point approx. 87cm (341/4”) from the unit-side cable connector (Fig.
3), and connect the leading end of the CN-2
connector to the power supply board. (Fig. 4)
2. (1)Using cable holders, fix the 5P cable at the
bottom of the handlebar pipe of the main unit
frame. (2)Fix the cable at the marked point of
the cable to the handlebar pipe just beneath
the horizontal frame. (3)Pass the 5P cable
along with the handlebar pipe, and the sagging
portion should be binded with a cable holder.
(Fig. 4)
Power Supply Board
Unit-Side Cable Connector
Horizontal Frame
87cm (34-1/4”)
Mark
this point.
Fig. 3
(2)
(3)
Fig. 4
Cable Holders
(1)
Fig. 5
3. Connect the cable connector to the control unit,
and apply the connector cover. Then, fix the
control unit to the handlebar post by using four
screws. (Fig. 1)
4. Provisionally turn on the power, and check if
the control unit works fine.
5. Fix the 5P connector to the handlebar post with
the cable holder.
6. Mount the frame cover.
Reference
Handlebar Pipe
See the Section D-1 "Removing
the Frame Covers."
Cateye ergometer Service Manual
39
Model
ES-2
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the 5P Cable : For the model EC-1600 (1)
● Removing the Existing Cable
5P Cable Handlebar Post
1. Loosen the four screws which fix the control
unit to remove the control unit. Also, remove
the cable connector. (Fig. 1) Slide the inner
handlebar post cover upward, and unplug the
cable connector. (Fig. 2)
2. Remove the screws of both the handlebar
stem and the outer handlebar post cover to
remove the 5P cable. (Fig. 3)
Cable
Connector
EC-1600
Inner Handlebar
Post Cover
Unplug
Screws
Screws
Fig. 1
Fig. 2
Fig. 3
Power Supply Board
5P Cable within the Frame
Handlebar Pipe
1. Remove the frame cover.
Reference
Horizontal Frame
See the Section D-1 "Removing
the Frame Covers."
(2)
(3)
2. Remove the CN-2 connector at the end of the
5P cable from the power supply board. (Fig. 4)
3. Cut the cable holders which fix the 5P cable to
the handlebar pipe, and remove the 5P cable.
(Fig. 5)
Cable Holders
Fig. 4
To be continued on the next page.
(1)
Fig. 5
Cateye ergometer Service Manual
40
Handlebar
Stem Cover
Model
ES-2
EC-1200
EC-1600
EC-3600
Replacing the 5P Cable : For the model EC-1600 (2)
● Mounting the Brand New Cable
5P Cable within the Handlebar Post
1. Using cable holders, bind the 5P cable, leaving
approx. 5 cm (2”) portion from the control unit
side cable connector, to the handlebar post. (Fig.
11) Assemble the handlebar post cover and
the handlebar stem cover. (Fig. 8)
2. Connect the cable connector to the control unit,
and fix the unit to the handlebar post by using
four screws. (Fig. 6)
10 cm (4”)
Cable Connector
5 cm (2”)
(1)
Cable Holder
(3)
Cable Holders
Fig. 11
5P Cable within the Frame
1. Connect the CN-2 Connector at the end of the
5P cable to the power supply board. (Fig. 9)
2. (1)Using cable holders, fix the 5P cable to the
frame, leaving the extra portion of 10 cm (4”)
from the top of the handlebar pipe. (2)
Fix
the 5P cable at the bottom of the handlebar
pipe. (3) Pass the 5P cable along the handlebar
pipe, and bind the sagging portion to the point
(3) by using cable holders. (Fig. 12)
(2)
Fig. 12
3. Provisionally connect the intermediate cable
connector, and turn on the power. Then, check
if the control unit works fine.
4. Mount the frame cover to restore the original
shape.
Reference
See the Section D-1 "Removing
the Frame Covers."
Cateye ergometer Service Manual
41
EC-3700
EC-C400
EC-C400R
Model
ES-2
EC-1200
EC-1600
EC-3600
Replacing the 5P Cable : For the model EC-3600, EC-3700 & EC-C400R
● Removing the Existing Cable
1. Loosen the four screws which fix the control
unit to remove the control unit. Also, remove
the cable connector. (Fig. 1)
Control Unit
2. Remove the frame cover.
5P Cable
Reference
Power Supply Board
See the Section D-2 "Removing
the Frame Covers."
3. Remove the 5P connector from the power
supply board. (Fig. 2)
Screws
Fig. 1
Fig. 2
4. Cut the cable holders which fix the cable to
remove the 5P cable.
10 cm (12”)
Power Supply Board
● Mounting the Brand New Cable
(1)
1. Leaving approx. 30 cm (12”) from the end of
the frame, fix the 5P cable to the frame by
using cable holders.
Cable Holders
(2)
2. Connect the 5P cable to the power supply
board, and bind the sagging portion to the
point (2) of the frame. (Fig. 3)
3. Provisionally turn on the power, and check if
the control unit works fine.
4. Mount the frame cover.
Reference
Fig. 3
See the Section D-2 "Removing
the Frame Covers."
Cateye ergometer Service Manual
42
EC-3700
EC-C400
EC-C400R
Model
ES-3
EC-1200
EC-1600
EC-3600
Replacing the Power Supply Board (1)
[1] Replacing the Power Supply Board
Power Supply Board
1. Remove the frame cover.
Reference
Power
Supply Board
See the Sections D-1 & D-2
"Removing the Frame Covers."
2. Remove all connectors CN-1, CN-2, CN-3 and
CN-4 which are connected to the power supply
board.
3. Loosen the two screws which fix the power
supply board to remove the board. (Fig. 1)
EC-1200 & 1600 C400
4. Securely fix the brand new power supply board
by using two fixing screws.
5. Connect three connectors, CN-2, CN-3 and
CN-4.
Power Supply
Board
Fixing Screws
Fig. 1
Cateye ergometer Service Manual
43
EC-3600 & 3700 C400R
EC-3700
EC-C400
EC-C400R
Model
ES-3
EC-1200
EC-1600
EC-3600
EC-3700
Replacing the Power Supply Board (2)
[2] Adjustment of Coil Current Value
Power Supply Board A
1. Connect the cables for measuring coil current
between the female connector of the solenoid
coil and the male connector (CN-1) on the
power supply board, and then connect the
cables to an ammeter. (Fig. 2)
2. Turn on the power switch of the main unit, set
the control unit to the manual mode, set the
load display to 4.0 kg•m, and start the system.
3. Adjust the potentiometer (as shown in Figs. 3
and 4) on the power supply board with a bladehead screwdriver so that the coil current will be
the value indicated on the workload unit
solenoid coil. (A clockwise turn will increase
the current, while a counter-clockwise turn will
reduce the current.)
Example: When the indication is 630 as shown
in Fig. 5, adjust the potentiometer
so that the coil current value will be
630mA.
4. Upon completion of the adjustment, detach the
cable for measuring coil current, and connect
the CN-1 connector directly to the power
supply board.
Potentiometer
Cable for
Measuring
Coil Current
Fig. 3
Fig. 2
Power Supply Board B
Solenoid
Coil
Location of Coil
Current Value
Indication
I mA
COIL
LOT No.
Potentiometer
Fig. 4
Fig. 5
Cateye ergometer Service Manual
44
K6020
EC-C400
EC-C400R
Model
ES-4
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Correcting the Position of Solenoid Coil (1)
Perform the positional correction of the core slit
section after detaching the frame cover and turning
off the power.
Reference
EC-1200
Workload Unit Reinforcing
Metal Base
Workload Unit Reinforcing
Metal Base
See the Sections D-1 & D-2
"Removing the Frame Covers."
[1] Correction with Nuts of Workload Unit Reinforcing
Metal Base
This correction is a minor correction method which
allows adjustment by the fastening force of the
frame-side nuts of the workload unit reinforcing metal
base.
1. Check the contacting area by slowly rotating
the copper disk plate with your hands.
Caution
Be careful that the copper disk
Workload Unit Reinforcing
Metal Base Lock Nut
EC-1200 1600 C400
Solenoid Coil
Workload Unit
Reinforcing Metal
Base
plate does not cause injury to your
hands.
Be careful not to bend or damage
the copper disk plate.
Move to
the Left
Lock Nut
Workload Unit Reinforcing
Metal Base Lock Nut
EC-3600 3700 C400R
Core Slit
ON
Solenoid Coil
OFF
Copper Disk Plate
Core Slit
Copper Disk Plate
Core
Core
Move to
the Right
Belt
I mA
I mA
COIL
COIL
Fig. 1
Solenoid Coil
❍ Correct Position
Fig. 2
Cateye ergometer Service Manual
45
Solenoid Coil
✕ Copper disk plate contacts the core.
Fig. 3
Model
ES-4
EC-1200
EC-1600
Correcting the Position of Solenoid Coil (2)
2. Adjust the position of the two lock nuts on the
workload unit reinforcing metal base in the
following procedures. (Fig. 1)
The base is fixed by the fastening force of the
two lock nuts.
A. Loosen the two lock nuts temporarily.
(Fig.1).
B. If the right side of the copper disk plate
makes contact with the core as shown in
Fig.3, fasten the left-side nut. The plate
moves to the left gradually. Adjust the plate
until it comes close to the center of the core
center. (Fig.2). At this position, rotate the
plate slowly, and check for any contact over
the entire area of the plate.
C. Fasten the lock nuts once again.
[2] In case correction is not possible by the method
stated in [1].
Replace the whole workload unit.
Reference
See the Section MS-1 or MS-2
"Replacing the Workload Unit."
Cateye ergometer Service Manual
46
EC-3600
EC-3700
EC-C400
EC-C400R
Model
ES-5
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the CDC Sensor (1)
1. Remove the frame cover.
Reference
See the Sections D-1 & D-2
"Removing the Frame Covers."
Power Supply Board
Power Supply
Board
2. Detach the CN-3 connector from the power
supply board. (Fig. 1)
CDC Sensor
3. Cut the cable holders which fix the CDC sensor
cable to the frame.
4. Remove the defective CDC sensor set by
loosening the screws, and mount and fix the
brandnew CDC sensor set. (Fig. 2)
CDC Sensor
Reference
EC-3600 & 3700 C400R
EC-1200 & 1600 C400
5. Adjust the gap between the surface of CDC
sensor and the surface of CDC magnet to be
approx. 2 mm. (Fig. 3)
CDC Sensor
Power Supply Board
If the gap is inadequate, bend the
metal base to secure the specified
gap.
CDC
Metal Base
Approx.
2 mm
Pulley 1-A
CDC Sensor
CN-3 Connector
Magnet
Fig. 1
Fig. 2
Cateye ergometer Service Manual
47
Fig. 3
Model
ES-5
EC-1200
EC-1600
Replacing the CDC Sensor (2)
6. Securely connect the CN-3 connector to the
power supply board. (Fig. 1)
7. Rotate the crank, and check if the pedal
cadence will be displayed on the control unit.
8. Fix the CDC sensor cable to the frame by
using cable holder. (Fig. 5)
Cable Holder
9. Assemble the frame cover.
Reference
See the Sections D-1 & D-2
"Removing the Frame Covers."
Fig. 5
Cateye ergometer Service Manual
48
EC-3600
EC-3700
EC-C400
EC-C400R
Model
ES-6
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the Panel Keyboard
1. Remove the control unit by loosening four
screws. Also remove the cable connector from
the control unit. (Fig. 1)
Control Unit
2. The control unit can be separated into upper
and lower parts when the eight screws on the
bottom of the lower body of the unit are
removed (Fig. 2). Be careful to separate them
slowly since the upper and lower bodies are
connected with a flat cable.
3. Remove the connector on the panel keyboard
which is located at the upper body side, loosen
the ten screws on the substrate, and remove
them from the upper body. (Fig. 3)
Substrate
Cable
Connector
Connector
Control Unit
Fig. 1
Fig. 2
Fig. 3
Control Unit
4. Since the panel keyboard is fixed to the control
unit with silicon, cut the silicon with a sharp
cutter (Fig. 4). Peel the panel keyboard off the
surface of upper body. (Fig. 5)
Upper Body
5. If the silicon remains at the upper body, remove
it thoroughly.
6. Place the brandnew panel keyboard. The
cable from the keyboard should be pulled in
through the hole on the upper body. Press and
adhere the panel keyboard in position.
Substrate
Fixing Screw
Screw
Silicon
Fig. 4
Panel Keyboard
Silicon
Fig. 5
Fig. 6
7. Apply silicon at two depicted areas to prevent
intrusion of sweat. (Figs. 4 and 6)
8. Mount the substrate and fix it with ten screws,
and insert the connector of the panel keyboard.
(Fig. 3)
TitleNo
9. Put the upper and lower body together, and fix
them with eight screws.
10. Connect the cable connector to the control
unit, and mount the unit to the main unit.
Cateye ergometer Service Manual
49
Model
ES-7
EC-1200
EC-1600
EC-3600
Replacing the Button Panel
1. Insert a thin cutting knife, while paying cautions
not to damage the control unit, in between the
button panel and the body, and carefully peel
off the button panel. (Fig. 1 and 2)
L
TRO
HR CON
E
ANC
ADV OBIC
AER
OBIC
AER
GHT
WEI
HIL
S
LOS
L
1
S
ER ATE
PR ES
TO OP
"
AL LY
MA NU
UI CK
2
3
"Q
AL
ERV
INT
1
2
Caution
QU
3
Be careful that the blade of the
INT
HIL
AN T
NST
CO TTA GE
WA
HR
CO NTR
cutter does not cause injury to your
hands.
2. Clean the adhesive agent, if any, on the control
unit before placing a brandnew button panel.
Reference
Sufficiently press the button panel
thus placed.
ICK
AL
ERV
T
STAR
L
MO
DE
OL
S
NEST
FIT
TES
STOP
Control Unit
Button Panel
EC-1200 3600
Control Unit
EC-C400 C400R
Fig. 2
Fig. 1
Cateye ergometer Service Manual
50
Button Panel
EC-3700
EC-C400
EC-C400R
Model
ES-8
EC-1200
EC-1600
Replacing the Printer
1. Open the control unit into upper and lower
bodies by referring to the Section ES-6 "Replacing the Panel Keyboard (1) & (2)."
CN-2 Connector
Printer Unit
2. Unit is fixed to the lower body with two screws.
Remove these two screws. (Fig. 1)
3. The printer unit can be removed after detaching
cable connectors CN-2 and CN-3 of the printer
unit. To remove connector CN-2, pull it, lifting
the printer unit upward. (Fig. 2)
4. Connect the connector CN-2 of the brandnew
printer unit. Then, connect CN-3. For the
connection, press it while moving it to right and
left side alternatively.
Printer Fixing Screws
Fig. 1
CN-3 Connector
Fig. 2
5. Fix the printer unit with two screws. (Fig. 1)
6. Put the upper and lower bodies together, and
fix them with eight screws.
7. Adjust the printing darkness by referring to the
Section ES-9 "Adjusting the Printing Darkness."
8. Mount the control unit to the main unit.
Cateye ergometer Service Manual
51
EC-3600
EC-3700
EC-C400
EC-C400R
Model
ES-9
EC-1200
EC-1600
EC-3600
Adjusting the Printing Darkness
1. Remove the control unit from the main unit.
(Fig. 1)
Upright Type
Recumbent Type
2. Loosen four screws on the bottom of the
control unit, and remove the cable connector
from the unit. (Fig. 1)
3. Remove the black metal base on the bottom of
the control unit. (Fig. 2)
4. Provisionally connect the 5P connector on the
bottom of the control unit to the main unit.
5. Turn on the power. Check if the printer symbol
appears on the LCD panel and the printer is in
the operating condition.
Control Unit
Cable
Connector
Cable
Connector
Control Unit
Fig. 1
6. Check if the thermal paper is set in position.
7. Adjustment should be done with the control
unit positioned horizontally. Press the ADV
button on the control panel twice to perform a
test printing. A counter-clockwise turn of the
potentiometer PR on the bottom of the control
unit will decrease the darkness, while a
clockwise turn will increase it (Fig. 2). Set it to
an appropriate darkness level. (An extreme
clockwise turn of the potentiometer may distort
the printed characters.)
Caution
DCV
PR
Potentiometer PR
Fig. 2
Never touch the potentiometer
DCV.
Cateye ergometer Service Manual
52
EC-3700
EC-C400
EC-C400R
Model
ES-10
EC-1200
EC-1600
Paper Jamming in Printer
1. Open the control unit into upper and lower
bodies by referring to the Section ES-6 "Replacing the Panel Keyboard (1) & (2)."
Pincette
2. Remove the jammed paper with a tweezer or
the like. (Fig. 1)
3. Assemble the control unit by referring to the
Section ES-6 "Replacing the Panel Keyboard
(9) & (10)."
4. Set the printer paper.
Reference
See the Operation Manual.
Printer Unit
Fig. 1
Cateye ergometer Service Manual
53
EC-3600
EC-3700
EC-C400
EC-C400R
Model
ES-11
EC-1600
EC-3600
EC-3700
EC-C400
Replacing the Pulse Sensor Jack and Pulse Sensor Jack Board (1)
■Replacing the Pulse Sensor Jack Board
1. Turn off the power and open the control unit
which accesses the upper and lower bodies.
Reference
EC-1200
Pulse Sensor
Jack Board
Pulse Sensor
Jack Board
Pulse Sensor
Jack Board
See the Section D-3 "Decomposition of a Control Unit ".
2. In the case of the three cables (or four in the
case of the ES-C400 and ES-C400R) soldered
to the board, number the cables so that they
can be matched to cable numbers 1 to 4 on the
board. (Fig.1)
Remove the cables using a soldering iron.
Remove the defective board.
Cable
Cable
EC-1200 & EC-3700
EC-1600 & EC-3600
Fig. 1
3. Insert a brand new board and solder the cable
in place. Match the cables to the numbered
cables on the board.
4. Bring the upper and lower bodies together and
fasten them temporarily with the eight screws.
5. Insert the pulse sensor and check whether or
not the control unit displays a value.
Cable
Fig. 2
6. Fasten the eight screws.
Cateye ergometer Service Manual
54
EC-C400 & EC-C400R
EC-C400R
Model
ES-11
EC-1200
EC-1600
Replacing the Pulse Sensor Jack and Pulse Sensor Jack Board (2)
7. Mount the control unit on the main unit.
Warning
Pulse Sensor Jack
Be sure to turn off the power
before starting work.
Particularly, in case of the ECC400 and EC-C400R, the parts
indicated in figure 2 are operating
at high voltage and may cause
electric shock. Furthermore,
residual electric current is likely to
be present for a little while after the
power is turned off. Before restarting work, wait a few moments after
the power has been turned off.
Solder
Fig. 3
■Replacing Only the Pulse Sensor Jack
1. Turn off the power and open the control unit
which accesses the upper and lower bodies.
Reference
See the Section D-3 "Disassembly
of a Control Unit ".
2. Lift the ear sensor jack board but not to the
extent that the cable will become taut, and
remove the jack with a soldering iron. Excessive solder should be removed using solder
remover, etc.
3. Solder a brand new pulse sensor jack in place.
(Fig.3)
Cateye ergometer Service Manual
55
EC-3600
EC-3700
EC-C400
EC-C400R
Model
ES-12
EC-1600
EC-3600
EC-3700
Replacing the HR Receiving Board (1)
1. Turn off the power and open the control unit
which accesses the upper and lower bodies,
Reference
EC-1200
Connector
HR Receiving
Board
See the Section D-3 "Disassmbly
of a Control Unit ".
2. Remove the connector from the reception
board. (Fig.1)
3. Loosen the four screws to remove the board.
(Fig.1)
4. Install a brand new board, securing it with four
screws. Insert a connector.
HR Receiving
Board
EC-C400 & EC-C400R
Connector
EC-1600 & EC-3700
Fig. 1
5. Bring the upper and lower bodies together and
secure them with eight screws.
EC-C400 & EC-C400R
EC-1600 & EC-3700
Fig. 2
Cateye ergometer Service Manual
56
EC-C400
EC-C400R
Model
ES-12
EC-1200
EC-1600
Replacing the HR Receiving Board (2)
6. Install the control unit in the main unit.
Warning
Be sure to turn off the power
before starting work.
Particularly, in case of the ECC400 and EC-C400R, the parts
indicated in figure 3 are operating
at high voltage and may cause
electric shock. Furthermore,
residual electric current is likely to
be present for a little while after the
power is turned off. Before restarting work, wait a few moments after
the power has been turned off.
Caution
Fig. 3
The HR reception board is standard in the case of equipment for
export while it is optional in the
case of equipment sold on the
domestic market. For information
related to installation (in the case
of products sold on the domestic
market), follow the instructions in
the operation manual of the
Reception Board Kit. Be sure the
power is turned off. Before restarting work, wait a few moments after
the power has been turned off.
Cateye ergometer Service Manual
57
EC-3600
EC-3700
EC-C400
EC-C400R
Model
MS-1
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the Workload Unit (w/o Flywheel) (1)
■ Removing the Workload Unit
1. Remove the frame cover.
Reference
Power Supply
Board
See the Section D-1 "Replacing
the Frame Covers."
CN-1 Connector
2. Detach the CN-1 connector on the power
supply board.
3. Using a nipper or the like, cut the cable holder
which fixes the CN-1 connector, while paying
attention not to damage the cable. (Fig. 2)
EC-1200
Power Supply
Board
Workload Unit
Fig. 1
Cable Holder
Fig. 2
4. Remove the crank pulley 1-A set.
Reference
See the Section MS-8 "Replacing
the Crank Pulley 1-A Set."
Also, remove the timing belt together with the
crank pulley 1-A set.
5. Using a wrench, loosen the nuts, which fix the
workload unit reinforcing metal base, on both
the workload unit side and the frame side, and
remove the metal base. (Fig. 3)
Workload Unit
Reinforcing Metal Base
Workload
Unit
Workload Unit
Fixing Metal Base
Fig. 3
Fig. 4
6. Remove the hexagonal head bolts securing the
workload unit (four points at the right and left)
as well as the bolt securing the workload unit
metal base. Lift the entire unit upward and off
the base, and then lift it either to the right or left
to remove it completely.
TitleNo
Caution
Be careful that your hands are not
injured by the copper disk plate
when lifting the unit.
Be careful not to bend or damage
the plate.
Cateye ergometer Service Manual
58
Workload Unit Fixing Bolt
Model
MS-1
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the Workload Unit (w/o Flywheel) (2)
■ Mounting the brand new Workload Unit
1. Assemble a brand new workload unit so that it
will engage with the workload unit mounting
metal base of the frame. (Fig.1)
Caution
Be careful that your hands are not
injured by the copper disk plate.
Be careful not to bend or damage
the plate.
2. Tighten the crank bolt by using a cotterless
gear crank removing/ fastening tool and a
wrench (Figs. 2 and 3). Tightening torque
should be 350kg cm to 400kg·cm, and tighten
the bolt until the end of the crank shaft can
level with the end surface of the bolt. Then, put
Workload Unit
Workload Unit
Fixing Metal Base
Cotterless Gear Crank
Removing/Fastening Tool
Cotterless Gear Crank
Removing/Fastening Tool
Fig. 1
Fig. 2
Fig. 3
Timing Belt
Timing Belt
Idler A Set
the crank cap with a coin or the like. (Fig. 4)
3. Position the timing belt on the pulley 1-B.
(Fig.4)
4. Position idler spring A on the pawl of the idler A
set. (Fig.5)
Caution
Idler Spring A
Pulley 1-B
Fig. 4
Fig. 5
Be careful that the end of the
spring does not cause injury to
your hands.
5. Position the timing belt on the pulley 1-A set.
The entire timing belt can be positioned by
rotating the crank forward (Fig.6)
Caution
Be careful not to pinch your fingers
between the timing belt and crank
pulley 1-A set.
Cateye ergometer Service Manual
59
Crank Pulley 1-A Set
Fig. 6
Model
MS-1
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the Workload Unit (w/o Flywheel) (3)
6. Adjust the position of the workload unit so that
the tension of the timing belt in the loaded area
is optimal. Move the workload unit back and
forth so that the longer edge of the derailleur
fixing metal base is perpendicular to idler
spring A. (Fig.7)
Caution
EC-1200
Be careful that your hands are not
injured by the copper disk plate.
Be careful not to bend or damage
the plate.
Workload Unit
Reinforcing Metal Base
Workload Unit Fixing
Metal Base Bolt
Idler A Set
90
Lock Nut
Workload Unit Fixing Bolt
Idler Spring A
Fig. 7
Fig. 8
7. Tighten the workload unit fixing bolts securing
the workload unit (four points, at the right and
left) as well as the bolt for the base with a
spanner. (Fig. 8) The tightening torque is 90
kg/cm to 120kg/cm.
8. Assemble the workload reinforcing metal base
in between the bolts at the workload side and
the frame side, and tighten the bolts with nuts.
(Fig. 9)
* In case the nut is screwed in at the position
where the workload-unit-side workload unit
metal base is supposed to be mounted,
remove the nut.
* The tightening torque at the workload unit side
should be 90kg·cm to 120kg·cm, and the nut at
the frame side should be provisionally tightened.
Cateye ergometer Service Manual
60
Fig. 9
Workload Unit
Side Bolt
Model
MS-1
EC-1200
EC-1600
Replacing the Workload Unit (w/o Flywheel) (4)
■ Checking the Positions of Copper Disk Plate and
Solenoid Coil Core Slit
● Regarding the workload unit, positions of
copper disk plate and solenoid coil core slit
have been adjusted before mounting the
frame so that they will not touch each other
while the plate is rotating. However, due to
positional distortion caused by tightening
the bolts while the frame is being mounted,
the copper disk plate may touch the core.
(Fig. 1)
Correct Position
Core Slit
Copper Disk Plate
Core
Fig. 1
● Rotate the copper disk plate slowly to check
if it does not touch the core. If it does, it is
necessary to eliminate the positional
distortion caused by the tightening.
Caution
When the copper plate is rotating,
keep hands away from unit.
Reference
See the Section ES-4 "Correcting
the Position of Solenoid Coil."
Cateye ergometer Service Manual
61
EC-3600
EC-3700
EC-C400
EC-C400R
Model
MS-1
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the Workload Unit (w/o Flywheel) (5)
Correction Method
Correction can be made by tightening the frame-side
nuts of the workload reinforcing metal base. Tighten
the metal base toward the direction in which the
positional correction of the copper disk plate should
be made, until the plate comes close to the center of
the core slit (Fig. 1).
Reference
Power Supply Board
Workload Unit
Reinforcing Metal Base
Frame-Side Nut
CN-1 Connector
Workload-UnitSide Nut
See the Section ES-4 "Correcting
the Position of Solenoid Coil."
1. After checking the correction direction, use a
wrench to tighten the frame-side nut of the
workload unit reinforcing metal base. Give the
even tightening to both right and left sides.
CN-1 Female
Connector
Fig. 2
Fig. 3
Power Supply Board A
2. As shown in Fig. 3, set a cable for measuring
coil current in between the CN-1 female
connector and the CN-1 male connector at the
side of power supply board, and connect the
cable to an voltmeter.
3. Turn on the power switch of the main unit, set
the control unit to the manual mode, select the
torque at 4.0kg·m, and start the system.
Cable for Measuring
Coil Current
Power Supply Board B
I mA
COIL
LOT No.
K6020
Potentiometer
Fig. 4
Fig. 5
4. Adjust the volume of the power supply board
(Fig. 5 and 6) with a driver until the coil current
rate is the same as the value (Fig.4) displayed
on the solenoid coil in the workload unit.
Example: As shown in Fig. 3, when 630 is
indicated, adjust the potentiometer so that the
coil current will be 630mA.
Cateye ergometer Service Manual
62
Potentiometer
Fig. 6
Model
MS-1
EC-1200
EC-1600
Replacing the Workload Unit (w/o Flywheel) (6)
5. After having adjusted the coil current, remove
the measuring cable, and connect the female
connector of the CN-1 cable directly to the
male connector at the power supply board side.
6. Fix the cable onto the seat pipe with cable
holders.
■ Adjusting the Flywheel
1. Adjust the flywheel by referring to the Section
MS-3 "Adjusting the Flywheel."
Cateye ergometer Service Manual
63
EC-3600
EC-3700
EC-C400
EC-C400R
Model
MS-2
EC-1200
EC-1600
EC-3600
EC-3700
Replacing the Workload Unit (w/ Flywheel) (1)
■ Removing the Workload Unit
Flywheel
1. Remove the crank pulley 1-A set and the
timing belt.
Reference
See the Items 1 to 4 in Section
MS-1 "Replacing the Workload
Unit (w/o Flywheel) (1)."
2. Loosen the flywheel fixing nut which is fixed to
the flywheel metal base. (Fig. 1)
Workload Unit
Workload Unit
EC-3600 & 3700 C400R
ON
EC-1600
3. Remove the four bolts which fix the flywheel
metal base, and remove the plain belt. (Fig. 2)
Caution
Flywheel
OFF
Flywheel
Be careful that your hands are not
injured by the copper disk plate.
Be careful not to bend or damage
the plate.
Flywheel Fixing Nut
Flywheel Metal Base
Plain Belt
Flywheel Fixing
Metal Base
4. Remove the workload unit.
Reference
See the Items 5 to 6 in Section
MS-1 "Replacing the Workload
Unit (w/o Flywheel) (1)."
Flywheel Fixing
Nut
Fig. 1
Metal Base Fixing Screw
Fig. 2
Cateye ergometer Service Manual
64
EC-C400
EC-C400R
Model
MS-2
EC-1200
EC-1600
Replacing the Workload Unit (w/ Flywheel) (2)
■ Mounting the brand new Workload Unit
1. Assemble the brand new workload unit so that
it will engage with the workload unit mounting
metal base of the frame (Fig. 1).
Reference
See the Item 1 of the Section MS-1
"Replacing the Workload Unit (w/o
flywheel) (2)."
2. Hang the plain belt on the flywheel, and fix it to
the flywheel metal base with the flywheel fixing
nut.
3. Provisionally fasten the metal base fixing screw
(4 pieces) to the flywheel fixing metal base and
the frame respectively. (Fig. 2)
4. Install the workload unit.
Reference
See the Items 2 to 8 in Section
MS-1 "Replacing the Workload
Unit (w/o Flywheel) (2)."
■ Adjusting the Flywheel
1. Adjust the flywheel.
Reference
See the Section MS-3 "Adjusting
the Flywheel."
Cateye ergometer Service Manual
65
EC-3600
EC-3700
EC-C400
EC-C400R
Model
MS-3
EC-1200
EC-1600
EC-3600
Adjusting the Flywheel
■ Adjustment Method of Flywheel
Since the plain belt which delivers the rotation of both
the workload unit and flywheel requires an adequate
tension, a specified tension should be given to the
plain belt in the following adjustment procedures. For
this adjustment, a commonly available spring scale.
Flywheel Metal Base
Spring
Scale
Flywheel Metal Base
1. Set a heavy gauge wire around the flywheel
metal base as depicted in Fig. 1, and tie up the
both ends outside the frame.
Flywheel
Metal Base Fixing Screw
Wire
Fig. 2
2. Hang a commercial spring scale at the top of
the wire thus tied up, and lift the scale upward
with a pulling force of 5 to 6 kg.
3. Keeping this status, fully tighten the four metal
base fixing screws which had been fastened
provisionally. (Fig. 2)
Metal Base Fixing Screws
Fig. 1
Cateye ergometer Service Manual
66
EC-3700
EC-C400
EC-C400R
Model
MS-4
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the Timing Belt (1)
1. Remove the frame cover.
Reference
See the Sections D-1 & D-2
"Removing the Frame Covers."
Idler A Set
Crank Pulley
1-A Set
Screw
2. Remove the eight fixing screws and then
remove the pulley flange. (Fig.1)
3. Remove the timing belt at the upper part of the
crank pulley 1-A set first, and then rotate the
crank forward to remove the entire timing belt.
(Fig.2)
4. Removing idler spring A from the pawl of the
idler A set will allow the entire timing belt to be
removed. (Fig.3)
Pulley Frange
Fig. 1
Fig. 2
Fig. 3
Crank Pulley
1-A Set
Timing Belt
5. Install a brand new belt on the on pulley 1-B.
(Fig.4)
6. Position idler spring A on the pawl of the idler A
set. (Fig.3)
Caution
Be careful that the end of the
spring does not injure your hands.
Pulley 1-B
Fig. 4
Fig. 5
7. Position the timing belt on the crank pulley 1-A
set.
A forward rotation of the pulley 1-A set allows
the timing belt to be set correctly. (Fig.5)
Caution
Be careful not to pinch your fingers
between the timing belt and the
crank pulley 1-A set.
8. Secure the flange of the pulley with the fixing
screws.
Cateye ergometer Service Manual
67
Idler Spring A
Timing Belt
Model
MS-4
EC-1600
Replacing the Timing Belt (2)
9. Adjust the tension of the timing belt.
To carry out adjustment, loosen the workload
unit fixing screw and adjust the tension while
sliding the unit back and forth. (Fig.6)
Caution
EC-1200
Be careful that the belt is not too
tight.
Be careful not to injure your hands
with the copper disk plate.
Be careful not to bend or damage
the plate.
Workload Unit Fixing
Metal Base Bolt
Workload Unit Fixing Screw
Fig. 6
10. Assemble the frame cover.
Reference
See the Sections D-1 & D-2
"Removing the Frame Covers."
Cateye ergometer Service Manual
68
EC-3600
EC-3700
EC-C400
EC-C400R
Model
MS-5
EC-1200
EC-1600
EC-3600
Replacing the Pulley 1-B Set
1. Detach the timing Belt.
Reference
See the Section MS-4 "Replacing
the Timing Belt."
2. Hold the D-cut section on the pulley 1-B shaft
with a No.13 wrench, and remove the hexagon
U-nut. Then, pull off the pulley 1-B set by using
a pulley 1-B remover. (Figs. 1 & 2)
3. Mount the brand new pulley 1-B set, and firmly
tighten the hexagon nut. Tightening should be
done while holding the D-cut section with a
No.13 wrench. (Fig. 1)
Pulley 1-B
Pulley 1-B
ON
EC-3600 3700 C400R
EC-1200 1600 C400
Idler
Pulley 1-B
4. Install the timing belt.
Reference
OFF
Timing Belt
See the Section MS-4 "Replacing
the Timing Belt."
D-Cut Section
Pulley 1-B
Fig. 1
Hexagon U-Nut
Fig. 2
Cateye ergometer Service Manual
69
EC-3700
EC-C400
EC-C400R
Model
MS-6
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the Idler A Set
1. Remove the screw of the crank pulley 1-A set
to remove the pulley flange. (Fig.1)
2. Remove the timing belt at the upper part of the
crank pulley 1-A set first, and then rotate the
crank forward to remove the entire belt. (Fig.2)
Idler A Set
Idler A Set
3. Remove idler spring A from the pawl of the
idler A set. (Fig.3)
4. Remove the idler fixing bolt of the idler A set to
remove the idler A set. (Fig.4)
EC-3600 3700 C400R
EC-1200 1600 C400
5. Mount the brand new idler A set with idler fixing
bolt.
Crank Pulley 1-A Set
Screw
Idler A Set
6. Position idler spring A on the pawl of the idler A
set.
Caution
Be careful that the end of the
spring does not injure your hands.
7. Position the timing belt on the pulley 1-A set.
Rotate the pulley set forward to set the belt.
Caution
Be careful not to pinch your fingers
between the timing belt and crank
pulley 1-A set.
Pulley Frange
Fig. 1
Mounting Bolt
8. Mount the pulley flange with screws.
Idler A Set
Fig. 4
Cateye ergometer Service Manual
70
Idler Spring A
Timing Belt
Fig. 2
Fig. 3
Model
MS-7
EC-1200
EC-1600
EC-3600
Replacing the Idler B Set
1. Remove the frame cover.
Reference
See the sections D-1 & D-2
"Removing the Frame Covers."
Idler B Set
Idler B Set
2. Remove the idler B spring from the pawl of the
idler metal base. (Fig. 1)
3. Loosen the idler B mounting bolts, and detach
the idler B set. (Fig. 2)
4. Mount a brand new idler B set by using an idler
mounting bolt.
EC-3600 3700 C400R
EC-1200 1600 C400
5. Hang the idler B spring on the pawl of the idler
Caution
Idler B Set
Idler B Set
to give tension to the belt.
Be careful that the end of the
spring does not injure your hands.
Idler Mounting Bolt
Idler Spring B
Fig. 1
Fig. 2
Cateye ergometer Service Manual
71
EC-3700
EC-C400
EC-C400R
Model
MS-8
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the Crank Pulley 1-A Set (1)
■ Removing the CrankPulley 1-A Set
1. Remove the frame cover.
Reference
Crank Pulley 1-A Set
See the Sections D-1 & D-2
"Removing the Frame Covers."
2. Detach the timing belt.
Reference
See the Section MS-4 "Replacing
the Timing Belt."
3. Insert a flat had driver into the groove of the
crank cap to remove the crank cap. (Fig.2)
4. Use a cotterless gear crank removing/fastening
tool and a wrench, rotate the crank bolt to
remove it. (Fig. 3)
Crank Pulley 1-A Set
EC-3600 3700 C400R
EC-1200 1600 C400
Crank Pulley 1-A Set
Cotterless Gear Crank
Removing/Fastening Tool
5. Change the sides of a cotterless gear crank
removing/fastening tool, and rotate it clockwise
to remove the crank pulley 1-A set from the
crank shaft. (Fig. 4)
Crank Cap
Timing Belt
- to be continued to the next page -
Fig. 1
Fig. 2
Cotterless Gear Crank
Removing/Fastening Tool
Fig. 4
Cateye ergometer Service Manual
72
Fig. 3
Model
MS-8
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the Crank Pulley 1-A Set (2)
■ Assembling the Crank Pulley 1-A Set
Cotterless Gear Crank
Removing/Fastening Tool
1. Mount the gear crank (crank) to the crank shaft.
2. Securely fasten the crank bolt by using a
socket wrench (or by a cotterless gear crank
removing/fastening tool and a wrench). (Figs.
1 & 2)
Caution
Each of the cranks should be
positioned relative to each other to
form an angle of 180 °against the
gear. (Fig.3)
3. Clamp the crank cap.
Right-Side
Crank
Left-Side
Crank
Cotterless Gear Crank
Removing/Fastening Tool
Fig. 1
Fig. 2
Crank Pulley 1A Set
Fig. 3
Workload Unit Fixing
Metal Base Bolt
Screw
4. The timing belt should be first positioned on
pulley 1-B and then on the upper part of the
crank pulley 1-A set. A forward rotation of the
crank will allow the belt to be set correctly
(Fig.4)
Caution
Be careful not to pinch your fingers
between the timing belt and crank
pulley 1-A set.
Pulley Flange
Pulley 1-B
Fig. 4
Fig. 5
5. Mount the pulley flange with screws.
6. Adjust the tension of the timing belt.
To carry out adjustment, loosen the screws of
the workload unit (four points, at the right and
left) as well as the bolt which secures the metal
base, and then adjust the tension while sliding
the unit back and forth. (Fig.5)
Caution
Be careful that the timing belt is not
too tight.
Be careful not to injure your hands
with the copper disk plate.
Be careful not to bend or damage
the plate.
Cateye ergometer Service Manual
73
Workload Unit Fixing Screw
Fig. 6
Model
MS-8
EC-1200
EC-1600
Replacing the Crank Pulley 1-A Set (3)
7. Adjust the clearance between the magnet
mounted on the large gear and the CDC
sensor, and also adjust the positions of the
sensing lines.
Reference
See the Item (5) of Section ES-5
"Replacing the CDC Sensor (1)."
8. Turn on the power temporarily, and check
whether or not the pedal cadence is displayed
on the control unit.
9. Reassemble the frame cover.
Reference
See the Sections D-1 and D-2
"Removing the Frame Covers."
Cateye ergometer Service Manual
74
EC-3600
EC-3700
EC-C400
EC-C400R
Model
MS-9
EC-1200
EC-1600
EC-3600
EC-3700
Replacing the Cartridge BB Set (1)
■ REMOVAL
1. Remove the frame cover.
Reference
Cartridge BB Set
See the Sections D-1 & D-2
"Removing the Frame Covers."
2. Remove the crank pulley 1-A set from the crank
shaft (BB Axle).
Reference
See the Section MS-8 "Replacing
the Crank Pulley 1-A Set."
3. Remove the cartridge BB from the left side
using a cartridge BB removing tool and a
wrench. (Fig.1)
Reference
Cartridge BB Set
Loosen
Loosen
Cartridge BB
Cartridge BB Removing Tool
Cartridge BB Removing Tool
(SHIMANO TL-UN74S/BB)
4. Remove the BB fixing cup using a cartridge BB
removing tool and a wrench. (Fig.2)
The CDC sensor (metal base) will be removed
at the same time.
Caution
EC-3600 3700 C400R
EC-1200 1600 C400
The BB fixing cup is a left winding
screw. To loosen the screw, turn it
to the right.
Fasten
Fasten
Cartridge BB Removing Tool
Fig. 1
CDC Sensor
Fig. 2
Cateye ergometer Service Manual
75
EC-C400
EC-C400R
Model
MS-9
EC-1200
EC-1600
Replacing the BB Set (2)
■ ASSEMBLING
CDC Sensor
Metal Base
1. Install the right BB fixing cup. Be sure to install
the CDC sensor metal base first, before then
installing the fixing cup.
2. Mount cartridge BB. The tightening torque is
400kg/cm.
CDC Sensor
Approx.
2 mm
3. Install the crank pulley 1-A set.
Pulley 1-A
Reference
See the Section MS-8 "Replacing
the Crank Pulley 1-A Set."
Magnet
Fig. 3
4. Adjust the clearance between the CDC sensor
surface and the magnet surface to be approx.
2mm. (Fig. 3)
Reference
When the specified clearance has
not been established, bend the
metal base to have the clearance.
5. Turn on the power temporarily, and check
whether or not the pedal cadence is displayed
on the control unit.
6. Reassemble the frame cover.
Reference
See the Sections D-1& D-2
"Removing the Frame Covers."
Cateye ergometer Service Manual
76
EC-3600
EC-3700
EC-C400
EC-C400R
Model
MS-10
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the Post Spacer
■ REMOVAL
1. Remove the center cover, by referring to the
Section MS-19 "Replacing the Center Cover of
Upright Type."
Spacer Spring
Lock Nut
Post Spacer
Adjust Screw
Adjust Screw
Boss
2. Remove the lock nut located at the side of the
frame, and then remove the adjust screw. (Fig. 1)
Press in.
3. Pull out the spacer spring. (Fig. 1)
4. The post spacer can be pulled out upward
while the boss at the side of the post is being
pressed in with a screwdriver (for both right
and left sides). (Fig. 2)
Lock Nut
Fig. 1
Fig. 2
■ ASSEMBLING
1. Insert a brand new post spacer.
2. Insert the spacer spring, and slightly fasten the
adjust screw. (Fig. 3)
3. Insert the seat post (handleber post), and
adjust the adjust screw so that the post will
drop slowly.
4. Fasten the lock nut to lock the adjust screw.
5. Assemble the center cover, by referring to the
Section MS-19 "Replacing the Center Cover of
Upright Type."
Cateye ergometer Service Manual
77
Fig. 3
Model
MS-11
EC-1200
EC-1600
Adjusting the Spacer Spring
1. Remove the center cover, by referring to the
Section MS-19 "Replacing the Center Cover of
Upright Type."
Lock Nut
Adjust Screw
2. Slightly loosen the lock nut at the side of the
frame. (Fig. 1)
3. Fasten the adjust screw so that the seat post
will drop slowly.
4. Fasten the lock nut to fix the adjust screw.
5. Assemble the center cover, by referring to the
Section MS-19 "Replacing the Center Cover of
Upright Type."
Fig. 1
Cateye ergometer Service Manual
78
EC-3600
EC-3700
EC-C400
EC-C400R
Model
MS-12
EC-1200
EC-1600
EC-3600
EC-3700
Replacing the Inner Pipe Spacer
■ REMOVAL
1. Slide the seat pipe to the utmost back end, and
set it at a position where the screw head can
be seen through the hole on the top surface of
the seat pipe.
Inner Pipe
Spacer A
Stopper Screw
Pull out.
Inner Pipe
2. Remove the stopper screw. (Fig. 1)
3. Pull out the seat pipe and the inner pipe spacer
A, while depressing the two bosses, located at
the right and left sides of the seat pipe, at the
same time. (Fig. 2)
Caution
Pulling out the inner pipe will make
the machine unstable. As they are
heavy, be sure that two persons
work together to carry the units.
Boss
Inner Pipe
Seat Pipe
Fig. 1
Fig. 2
Inner Pipe Spacer A
Inner Pipe
Spacer B
Inner Pipe Spacer B
Insert.
4. Remove the spacer B at the end of the inner
pipe. (Fig. 3)
Seat Pipe
Inner Pipe
■ ASSEMBLING
1. Set a brand new inner pipe spacer B into the
seat pipe. (Fig. 4)
Caution
Inner Pipe
Fig. 3
Fig. 4
When installing each unit, be
careful not to compact or kink the
cord of the pulse sensor.
2. Insert the inner pipe spacer A and B together
into the seat pipe.
3. Align the hole on the top surface of the seat
pipe with the screw hole, and apply the stopper
screw. (Fig. 1)
Cateye ergometer Service Manual
79
EC-C400
EC-C400R
Model
MS-13
EC-1600
EC-3600
Replacing the Vertical Pipe Spacer
1. Remove the seat height lock knob, and pull out
the rear support pipe. (Fig. 1)
Caution
EC-1200
When holding the main body of the
unit, be careful when pulling out
the seat height locking knob.
2. Remove the rear support pipe spacer at the
rear support pipe insertion area on the top
surface of the seat pipe. The rear support pipe
spacer is fixed on the pipe with an adhesive
tape.
Seat Height
Lock Knob
Rear Support Pipe
Rear Support
Pipe Insertion Area
Fig. 1
Rear Support
Pipe Spacer
3. Apply and set a brand new rear support pipe
spacer with an adhesive tape. (Fig. 2)
Adhesive Tape
4. Insert the rear support pipe, and fix it with the
seat height lock knob.
Fig. 2
Cateye ergometer Service Manual
80
EC-3700
EC-C400
EC-C400R
Model
MS-14
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
Replacing the Leg Cover
■ REMOVAL
1. Remove the leg pipe from the main body. Also,
remove the leveling knob. (Fig. 1)
Leg Cover
Leveling Knob
2. Apply a screwdriver or the like to the damaged
leg cover, and knock the cover off, paying
attention not to damage the caster. (Fig. 2)
Screwdriver
Leg Cover
■ ASSEMBLING
1. Set the leg cover onto the leg, and hammer it
in. The use of a wood block is recommended
as a buffer. (Fig. 3)
Fig. 1
Fig. 2
* A direct hammering of the leg cover may
damage the leg cover.
Fig. 3
2. Mount the leveling knob and assemble it to the
frame.
Cateye ergometer Service Manual
81
EC-C400R
Model
MS-15
EC-1200
EC-1600
EC-3600
Replacing the Caster and Level Adjuster
1. Loosen the screw and remove the front leg
with casters (rear leg with level adjuster) from
the main unit (leg).
2. The caster (level adjuster) has been pressfitted into the front leg with casters (rear leg
with level adjuster). It can be removed by
hammering it through a wooden block. (Fig. 1)
3. Press fit a brand new caster (level adjuster)
with a hammer and a wood block. (Fig. 2)
Front Leg with Casters
(Rear Leg with
Level Adjuster)
Wood Block
Wood Block
4. Mount the front leg with casters (rear leg with
level adjuster) to the main unit (leg).
Front Leg with Casters
(Rear Leg with
Level Adjuster)
Caster (Level Adjuster)
Fig. 1
Fig. 2
Cateye ergometer Service Manual
82
EC-3700
EC-C400
EC-C400R
Model
MS-16
EC-1200
EC-1600
Replacing the Seat Post Knob
1. Pull out the seat post.
2. Remove the seat post knob by rotating and
loosening the guide screw in the counterclockwise direction.
Seat Post Knob
Knob
Rubber Base
3. Mount a brand new seat post knob by securely
tightening the guide screw.
4. Insert the seat post.
Guide Screw
Fig. 1
Cateye ergometer Service Manual
83
EC-3600
EC-3700
EC-C400
EC-C400R
Model
MS-17
EC-1200
EC-1600
Replacing the Lock Pin
1. Remove the lock pin by rotating and loosening
the guide screw in the counter-clockwise
direction.
Lock Pin
2. Mount a brand new lock pin by securely
tightening the guide screw.
Wrench
Guide Screw
Fig. 1
Cateye ergometer Service Manual
84
EC-3600
EC-3700
EC-C400
EC-C400R
Model
MS-18
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
Replacing the Crank Cover
■ REMOVAL
1. Remove both right and left pedals. (Fig. 1)
Upright Type
Crank
2. Loosen and remove the fixing screw on the
surface of the crank cover. The narrow-width
area of the crank cover should position in
between the frame cover and the crank. (Figs
2 & 3)
Recumbent Type
No.15 Wrench
ON
OFF
Pedal
Crank Cover
■ ASSEMBLING
1. Pass the crank through the hole on the crank
cover, and fix the crank cover onto the frame
cover with screws. (Figs. 2 & 3)
Fig. 1
Fig. 2
Crank Cover
2. Set the right and left pedals.
Fig. 3
Cateye ergometer Service Manual
85
EC-C400R
Model
MS-19
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the Center Cover of Upright Type
1. Loosen the four screws on the bottom of the
control unit, remove the control unit, and then
detach the cable connector. (Fig. 1)
Handlebar Post
2. For EC-1600, slide the inner pipe of the
handlebar post cover upward, and detach the
5P cable connector (Fig. 2). For EC-1200,
remove the cable holder from the handlebar
post.
3. Loosen the handlebar post knob, and pull out
the handlebar post from the main unit. (Fig. 3)
5P Cable
Fig. 1
Handlebar Post
Knob
5P Cable
Fig. 2
Fig. 3
Seat Post Knob
4. Pull the seat post knob upward, and pull out
the seat post from the main unit. (Fig. 4)
5. Loosen and remove the guide screw of the
seat post knob. (Fig. 5)
Handlebar Post
Cover
Seat Post Knob
Rubber Base
Seat Post
6. Remove the rubber base of the seat post knob.
(Fig. 6)
7. Slightly loosen the center cover fixing screws
(6 pieces), and remove the center cover by
pulling it upward. (Fig. 7)
Guide Screw
Fig. 4
8. The assembling of the center cover can be
made in the procedures opposite to the above.
Fig. 5
Center Cover
Center Cover
Fixing Screw
Fig. 7
Cateye ergometer Service Manual
86
Fig. 6
Model
MS-20
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
Replacing the Center Cover of Recumbent Type
* Remove the pulse rate sensor, if it is connected, before proceeding to the following
procedures.
Control Unit
Inner Pipe
1. Remove the control unit fixing screws (4
pieces) from the main unit. (Fig. 1)
2. Detach the cable connector from the control
unit. (Fig. 2)
3. Loosen and remove the inner pipe from the
joint metal base. (Fig. 3)
Caution
Pulling out the inner pipe will make
the machine unstable. As they are
heavy, be sure that two persons
work together to carry the units.
Control Unit Fixing Screw
Fig. 1
5P Cable
Joint Metal Base
Fig. 2
Frame Cover
Fixing Screw
Center
Cover
Inner Pipe
4. Remove the frame cover fixing screws, and the
frame cover will be separated into right and left
parts. (Fig. 4)
5. Remove the latch of the center cover from the
frame cover, and pull the center cover toward
the joint metal base to remove it. (Fig. 5)
6. Assembling of the center cover can be performed in reversed procedure of the above.
Caution
Joint Metal Base
Fig. 3
Frame Cover
Joint
Fig. 4
Fig. 5
When installing each unit, be
careful not to compact or kink the
cord of the pulse sensor.
Pull the 5P cable connector
through the hole in the center cover
and secure it provisionally with
adhesive tape to prevent it from
retracting. (Fig.5)
Cateye ergometer Service Manual
87
Model
MS-21
EC-1200
EC-3600
Replacing the Handlebar Grip
1. In case the handlebar grip is damaged, cut the
grip with a thin cutting knife and peel it off the
handlebar. (Fig. 1)
Caution
EC-1600
Brand new Grip
Be careful that the blade of the
cutter does not cause injury.
2. Fit a brand new handlebar grip onto the
handlebar, utilizing compressed air from a
compressor, etc. Press the grip into the
handlebar while applying compressed air at
one end. (Fig. 2)
Air Gun,
etc.
Handlebar
Existing Grip (Old)
Fig. 2
Fig. 1
* When a compressor is not available, apply a
soap water on the handlebar, and insert the
grip while twisting and pressing the grip.
* When the above replacing work is difficult to
achieve, remove the handlebar before the
work.
Cateye ergometer Service Manual
88
EC-3700
EC-C400
EC-C400R
Model
MS-22
EC-1600
Replacing the Printer Cover
1. Remove the control unit to separate upper and
lower bodies.
Reference
EC-1200
Printer Cover
See the Items (1 & 2) in Section
ES-6 "Replacing the Panel Keyboard."
2. Detach the existing printer cover, and mount
the brand new printer cover.
3. Bring the upper and lower body together and
assemble the control unit as one main unit.
Reference
See the Items (8 & 9) in Section
ES-6 "Replacing the Panel Keyboard."
Upper Body
of Control Unit
Fig. 1
Cateye ergometer Service Manual
89
EC-3600
EC-3700
EC-C400
EC-C400R
Model
MS-23
EC-1200
EC-1600
Replacing the Paper Cutter
1. Remove the control to separate upper and
lower bodies.
Reference
See the Items (1 & 2) in Section
ES-6 "Replacing the Panel
Keyboard."
Paper Cutter
2. Loosen and remove four screws. Also, remove
the spring. (Fig. 1)
3. Remove the existing printer cutter, and mount
a brand new paper cutter.
Caution
Be careful that the paper cutter
does not cause injury.
Screws
Spring
Fig. 1
4. Set the spring so that it will fit into the groove
of the paper cutter, and fix it with four screws.
5. Bring the upper and lower body together and
assemble the control unit as one main unit.
Reference
See the Items (9 & 10) in Section
ES-6 "Replacing the Panel
Keyboard."
Cateye ergometer Service Manual
90
EC-3600
EC-3700
EC-C400
EC-C400R
Model
MS-24
EC-1200
EC-1600
EC-3600
Replacing the Handle Stem
1. Turn off the power, loosen the four screws of
the handle stem and then remove the control
unit. (Fig.1)
Handlebar
Screw
Bolt
2. Remove the cable connector linked to the rear
of the control unit. (Fig.1)
Handle
Stem
3. Leave the handlebar lever loose. (Fig.1)
4. Loosen the bolt and pull the handle stem out
from the main unit. (Fig. 2)
Caution
Be careful not to remove the bolt
completely.
Handlebar Lever
Cable
Connector
Fig. 1
Fig. 2
5. Install a brand new handle stem and fasten the
bolt.
6. Carry out the steps above in reverse order to
reassemble handle stem.
Cateye ergometer Service Manual
91
EC-3700
EC-C400
EC-C400R
Model
PNR.780-6100
PNR.780-6101
PNR.780-6106
PNR.780-6102
PNR.780-6107
Unit: pieces
EC-1200 Control Unit(J) Ivory
EC-1200 Control Unit(E) Ivory
EC-1200 Control Unit(E) Black
EC-1200 Control Unit(G) Ivory
EC-1200 Control Unit(G) Black
PNR.780-6108 EC-1200 Control Unit Multi Ivory
PNR.780-6109 EC-1200 Control Unit Multi Black
unit: pieces
HR CON
TRO
EC-1200
EC-1600
PNR.781-6500
PNR.781-6501
PNR.781-6506
PNR.781-6502
PNR.781-6507
unit: pieces
EC-3600
EC-1600 Control Unit(J) Ivory
EC-1600 Control Unit(E) Ivory
EC-1600 Control Unit(E) Black
EC-1600 Control Unit(G) Ivory
EC-1600 Control Unit(G) Black
EC-3700
EC-C400
EC-C400R
PNR.781-5600 EC-3600 Control Unit(J)
PNR.781-5601 EC-3600 Control Unit(E)
PNR.781-5602 EC-3600 Control Unit(G)
unit: pieces
L
E
ANC
ADV OBIC
AER
AER
OBIC
WEIG
HT LOS
S
HILL
1
E
RAT
SS
PRE
TO OPE
LLY K"
MA NUA UIC
2
3
INTE
RVA
"Q
L
1
2
QU
ICK
L
STA
RT
VALUE ADJUST
DE
STOP
PNR.781-5900
PNR.781-5901
PNR.781-5916
PNR.781-5902
PNR.781-5917
unit: pieces
EC-3700 Control Unit(J) Ivory
EC-3700 Control Unit(E) Ivory
EC-3700 Control Unit(E) Black
EC-3700 Control Unit(G) Ivory
EC-3700 Control Unit(G) Black
PNR.080-6701 EC-C400 Control Unit(J)
PNR.080-6702 EC-C400 Control Unit(E)
PNR.080-6703 EC-C400 Control Unit(G)
unit: pieces
1
10
ESS
FITN T
TES
MODE
ADV
MO
L
MODE
RVA
RESET
HR
TRO
CON
L
1
INTE
HIL
NT
STA E
CON TAG
WAT
10
3
PNR.780-5160 EC-1600/3700 Panel Keybord
unit: sets
ADVANCE
SOUND ON/OFF
PNR.780-6121 EC-1200 Button Panel(J)
PNR.780-6120 EC-1200 Button Panel(E)
PNR.780-6122 EC-1200 Button Panel(G)
unit: sets
EC-1600
EC-1200
FITNESS
TEST
HR
CONTROL
CONSTANT
WATTAGE
HILL
INTERVAL
QUICK
MODE
START
VALUE ADJUST
MODE
ADVANCE
STOP
TitleNo
SOUND ON/OFF
PNR.781-5610 EC-3600 Button Panel(J)
PNR.781-5611 EC-3600 Button Panel(E)
unit: sets
PNR.000-0000 EC-C400/C400R Button Panel(J)
PNR.022-5481 EC-C400/C400R Button Panel(E)
PNR.022-5482 EC-C400/C400R Button Panel(G)
unit: sets
PNR.000-0000
PNR.780-6061
PNR.780-6062
PNR.780-6063
unit: sets
EC-1200 Decal(J)
EC-1200 Decal(E)
EC-1200 Decal(G)
EC-1200 Decal(F)
Cateye ergometer Service Manual
92
PNR.000-0000
PNR.780-6561
PNR.780-6562
PNR.780-6563
unit: sets
EC-1600 Decal(J)
EC-1600 Decal(E)
EC-1600 Decal(G)
EC-1600 Decal(F)
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
EC-3700
EC-1200
HILL
HR CONTROL
1
ADVANCE
AEROBIC
2
3
AEROBIC
INTERVAL
WEIGHT LOSS
1
2
3
TO OPERATE
MANUALLY PRESS
"QUICK"
PNR.000-0000 EC-3600 Decal(J)
PNR.781-5631 EC-3600 Decal(E)
PNR.781-5632 EC-3600 Decal(G)
unit: sets
PNR.000-0000 EC-3700 Decal(J)
PNR.781-5921 EC-3700 Decal(E)
PNR.781-5922 EC-3700 Decal(G)
unit: sets
PNR.000-0000 EC-C400/C400R Decal(J)
PNR.022-5471 EC-C400/C400R Decal(E)
PNR.022-5472 EC-C400/C400R Decal(G)
unit: sets
PNR.781-5930 EC-3700/C400R Unit Base
unit: pieces
PNR.722-6501 Thermal Paper
unit: sets
PNR.736-6000 EC-1600/3700 Printer Unit
unit: sets
PNR.780-5111 EC-1600/3700 Printer Cover
unit: pieces
PNR.780-1031 EC-1600/3700 Paper Cutter
unit: pieces
PNR.780-1020 Paper Case
unit: pieces
PNR.780-1030 Paper Roller
unit: pieces
PNR.780-1100 EC-1200/1600 Pluse Sensor Set(1M)
PNR.780-1101 EC-3600/3700 Pluse Sensor Set(2M)
PNR.780-1102 EC-1200/1600 Pluse Sensor
Set(1.5M)
unit: sets
PNR.780-1110 Pluse Sensor Cover Set
unit: sets
Cateye ergometer Service Manual
93
TitleNo
R
Model
PNR.780-1200 Sensor Clip
unit: pieces
PNR.737-5500
PNR.737-5511
PNR.737-5520
PNR.737-5523
unit: sets
PNR.703-3101 EC-3600/3700 Recumbent Seat
unit: sets
PNR.025-0030 EC-1200/1600 HORN TYPE
Handlebar Grip
PNR.725-0000 EC-1200 Handlebar Grip
PNR.780-6470 EC-1600 Handlebar Grip
PNR.781-5060 EC-3600/3700 Handlebar Grip
unit: pieces
AC Adapter (100V) J
AC Adapter (120V) UL
AC Adapter (220V) EC
AC Adapter (240V) UK
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
PNR.781-6140 AC Adapter (100V) J
PNR.781-6141 AC Adapter (120V) UL
PNR.781-6142 AC Adapter (240V) UK
PNR.781-6143 AC Adapter (220V) EC
(For EC-C400/C400R/5000)
unit: sets
PNR.781-9100 Saddle (SMP 1209)
unit: sets
PNR.724-3410 EC-1200 Handlebar
PNR.780-6450 EC-1600 Handlebar
unit: pieces
PNR.781-9000 EC-1200/1600 Handlebar Set
(HORN TYPE)
unit: pieces
PNR.781-5130 EC-3600/3700 Handlebar
unit: pieces
PNR.781-3200 Handlebar Cap
unit: pieces
PNR.781-0210 EC-1200/1600 Handlebar Post
unit: pieces
PNR.780-6430 EC-1600 Handlebar Post Cover Set
unit: sets
Cateye ergometer Service Manual
94
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
PNR.758-5000 EC-1200/1600 Handlebar Lever Set PNR.780-6170 EC-1200/1600 Handlebar Stem
unit: sets
unit: sets
PNR.785-1416 Adjusting Knob/Seat Hite Lock Knob PNR.780-6190 EC-1200/1600 Seat Post
unit: pieces
unit: pieces
PNR.780-6050 EC-1200/1600 Post Spacer Set
unit: sets
PNR.780-9610 EC-1200/1600 Seat Pillar
unit: pieces
PNR.780-6260 EC-1200/1600/C400 New Seat Pillar PNR.785-1417 EC-1200/1600 Seat Post Knob
unit: pieces
unit: pieces
PNR.781-5120 EC-3600/3700 Lock Pin
unit: pieces
PNR.780-6040 EC-1200/1600 Rubber Base for Knob
unit: pieces
PNR.781-5300 EC-3700/3600/C400R Grip
unit: pieces
Cateye ergometer Service Manual
95
PNR.780-6000 EC-1200/1600 Frame Cover(L/R)Ivory
PNR.780-6001 EC-1200/1600 Frame Cover(L/R)Black
unit: sets
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
200
EC-1
EC-1
200
R
R
PNR.781-5000 EC-3600/3700 Frame Cover(L/R)Ivory PNR.780-6010 EC-1200/1600 Center Cover
PNR.781-5001 EC-3600/3700 Frame Cover(L/R)Black unit: pieces
unit: sets
PNR.781-5500 EC-3600/3700 Center Cover
unit: pieces
C40
70
-3
EC
EC
EC
EC-
0
0
-3
60
-3
-3
EC
EC-
70
0
0
60
16
00
00
R
16
0
R
0
C40
EC-
EC-
PNR.780-6020 EC-1200 Crank Cover(L,R) Set
unit: sets
R
R
PNR.780-6420 EC-1600 Crank Cover(L,R) Set
unit: sets
PNR.781-5810 EC-3700 Crank Cover(L,R) Set
unit: sets
PNR.781-8100 EC-C400 Crank Cover(L,R) Set
unit: sets
PNR.781-5100 Pedal(L,R)
unit: sets
PNR.024-3700 Pedal Set (LU-214) L,R
unit: sets
PNR.781-9300 Pedal Belt E-16 (L,R)
unit: sets
EC
-C
4
0
0
R
R
0
0
4
-C
EC
PNR.781-5520 EC-3600 Crank Cover(L,R) Set
unit: sets
PNR.781-8110 EC-C400R Crank Cover(L,R) Set
unit: sets
Cateye ergometer Service Manual
96
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
PNR.024-3710 Pedal Belt Set (LU-214) L,R
unit: sets
PNR.780-6160 EC-1200/1600 Rear Leg with Level
Adjuster
unit: pieces
PNR.780-6160 EC-1200/1600 Mod. Rear Leg
unit: pieces
PNR.780-0140 EC-1200/1600 Leveler Set
unit: sets
PNR.724-3950 EC-1200/1600 Levelling Knob
unit: pieces
PNR.780-6180 EC-1200/1600 Caster Pipe Set
unit: sets
PNR.780-6550 EC-1600 Vibration-proof Rubber
unit: pieces
PNR.780-6445 EC-1200/1600 Front Leg with Cover Set
unit: sets
PNR.781-0140 EC-3600/3700 Leveler Set
unit: pieces
PNR.787-2409 EC-3600/3700 Caster Pipe Set
unit: pieces
PNR.780-6446 EC-1200/1600 Front Leg with Cover Set PNR.786-2409 EC-3600/3700 Rear Leg with Level
unit: sets
Adjuster
unit: pieces
Cateye ergometer Service Manual
97
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
PNR.781-0150 EC-3600/3700 Caster Set
unit: pieces
PNR.781-5030 EC-3600/3700 Pipe Spacer Set
unit: sets
PNR.781-5040 EC3600/3700 Rear Support Pipe
Spacer Set
unit: sets
PNR.780-7050 EC-1200B Workload Unit
PNR.780-7060 EC-1600B Workload Unit(w/Flywheel)
PNR.781-5581 EC-3700B/3600B Workload Unit
(w/Flywheel)
unit: pieces
PNR.780-2240 Freewheel Set
unit: sets
PNR.724-4802 Crank Cap
unit: sets
PNR.718-0450 EC-1200/1600 Workload Unit
Reinforcing Metal Base
unit: pieces
PNR.781-5580 EC-3600/3700 Workload Unit
Reinforcing Metal Base
unit: pieces
PNR.780-7030 Idler A Set
unit: sets
PNR.780-7040 Idler Spring A
unit: pieces
PNR.780-2220 Idler Set
unit: sets
PNR.720-1110 Idler Spring
unit: pieces
Cateye ergometer Service Manual
98
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
PNR.780-7010 Pulley 1-B
unit: pieces
PNR.781-9200 Cartrige BB(YST-986A)
unit: sets
PNR.780-6990 Pulley 1-A Set
unit: sets
PNR.780-7020 Pulley 2-A Set
unit: pieces
PNR.780-7000 Pulley Flange
unit: pieces
PNR.724-1021 EC-1600B/1200B Teethed Timing
Belt (P8M15-1192)
PNR.724-1022 EC-3700B/3600B Teethed Timing
Belt (P8M15-1080)
unit: pieces
PNR.780-6240 EC-1200/1600 Inlet Metal Base
unit: sets
PNR.780-6241 EC-3600/3700 Inret Metal Base
unit: sets
PNR.780-6030 EC-1200/1600 Inlet Cover
unit: sets
PNR.780-6220 EC-1200 5PCable
unit: sets
PNR.780-6480 EC-1600 5PCable (Upper)
PNR.780-6481 EC-1600 5PCable (Lower)
unit: sets
PNR.781-5550 EC-3600/3700 5PCable
unit: sets
Cateye ergometer Service Manual
99
Model
PNR.780-6241 CDC Sensor Set
unit: sets
PNR.780-6210 Power Supply Board
unit: sets
EC-1200
EC-1600
EC-3600
PNR.729-5010 Cable Clip Small (CV200)
unit: pieces
TO
EC-3700
EC-C400
EC-C400R
PNR.729-5025 Cable Clip Large (CV250)
unit: pieces
P
D
A
MS
C
Wi
rele
ss
He
art
Ra
te
Se
nso
r
P
TO
T
He
A
MS
C
Wi
rel
art
Ra
te
Se
nso
r
ess
C
A
R
D
PNR.718-5140 EC-1200 Cable Holder
unit: pieces
PNR.722-4950 Date Card
unit: sets
PNR.701-7002 Chest-belt & Pulse Sensor Kit
(TM-1600)
unit: pieces
PNR.169-9806 Chest-belt Set
unit: pieces
PNR.169-9826 Replacement Electrode Belt
unit: pieces
PNR.169-9816 Mounting Belt
unit: pieces
PNR.000-0000 Pulse Sensor Kit
unit: pieces
PNR.166-5150 Lithium Battery CR2032
unit: pieces
Cateye ergometer Service Manual
100
Model
EC-1200
EC-1600
EC-3600
EC-3700
EC-C400
EC-C400R
R
3
R
1
IS
-0
0R
P
31
0-
F-2
00
D
C
S
0R
50
-1
C
E
K
R2 1
Q
DC
IN
5V
OU
T
IN
PNR.781-5180 EC-3600/3700/C400R Tool kit
unit: sets
PNR.758-1000 Cotterless Gear Crank Removing/
Fastening Tool
unit: sets
PNR.781-9210 Cartrige BB Removing Tool
unit: sets
PNR.758-1010 Freewheel Set Removing Tool
unit: sets
PNR.758-1080 Pin Face Wrench
unit: sets
PNR.737-7000 Tester
unit: sets
PNR.747-8000 Coil Current Measuring Cable
unit: sets
PNR.780-6110
PNR.780-6111
PNR.780-6112
PNR.780-6113
unit: sets
EC-1200 Operating Instructions J
EC-1200 Operating Instructions E
EC-1200 Operating Instructions G
EC-1200 Operating Instructions F
PNR.780-6510
PNR.780-6511
PNR.780-6512
PNR.780-6513
unit: sets
EC-1600 Operating Instructions J
EC-1600 Operating Instructions E
EC-1600 Operating Instructions G
EC-1600 Operating Instructions F
Cateye ergometer Service Manual
101
R
R
R
PNR.701-5700 RS232C Communication Kit (100V) PNR.780-6350 EC-1200/1600/C400 Tool kit
PNR.701-5701 RS232C Communication Kit (120V) unit: sets
PNR.701-5703 RS232C Communication Kit (220V)
unit: sets
PNR.781-5700
PNR.781-5701
PNR.781-5702
PNR.781-5703
unit: sets
EC-3600 Operating Instructions J
EC-3600 Operating Instructions E
EC-3600 Operating Instructions G
EC-3600 Operating Instructions F
Model
EC-1200
EC-1600
EC-3600
rg
E
e 00
ey -C4 nual
at EC Ma
C ODELuction
¤
M
rg
E
e 00
ey -C4 nual
a t EC Ma
C ODELuction
¤
str
In
M
R
In
str
o
m
et
er
m
et
o
er
00
PNR.781-5990
PNR.781-5991
PNR.781-5992
PNR.781-5993
unit: sets
EC-3700 Operating Instructions J
EC-3700 Operating Instructions E
EC-3700 Operating Instructions G
EC-3700 Operating Instructions F
PNR.000-0000
PNR.080-6751
PNR.000-0000
PNR.000-0000
unit: sets
EC-3700
-C
40
0
RE
CU
NB
EEC
N-TC
B40I
K0ER
E
BIK
T
GH
I
R
UP
EC
EC-12
ON
OFF
EC-C400 Operating Instructions J
EC-C400 Operating Instructions E
EC-C400 Operating Instructions G
EC-C400 Operating Instructions F
PNR.000-0000
PNR.080-6761
PNR.000-0000
PNR.000-0000
unit: sets
EC-C400R Operating Instructions J
EC-C400R Operating Instructions E
EC-C400R Operating Instructions G
EC-C400R Operating Instructions F
Cateye ergometer Service Manual
102
R
EC-3700
EC-C400
EC-C400R
Model
1
PNR.752-1085 Hexagon Nut M8-3
unit: pieces
4
PNR.756-1412 Tapping Screw 4x12 with Washer
unit: pieces
EC-1200
EC-1600
EC-3600
2
EC-3700
EC-C400
EC-C400R
3
PNR.752-1063 Hexagon Nut M6-3
unit: pieces
PNR.753-5410 Screw Set M6x12
unit: pieces
PNR.750-9616 Screw Set(+) M6x16
unit: pieces
PNR.750-1390 Spacing Spring
unit: pieces
PNR.750-8616 Cross-recessed Head Hexagon
Screw M6x16
unit: pieces
PNR.750-6810 Seat Post Adjust Screw M8x10
unit: pieces
PNR.751-5330 Tapping Screw(2) 3x30
unit: pieces
PNR.751-5208 Tapping Screw(2) 2x8
unit: pieces
PNR.751-5206 Tapping Screw(2) 2x6
unit: pieces
5
6
PNR.753-6412 Tapping Screw(2) 4x12C
unit: pieces
Cateye ergometer Service Manual
103
Model
EC-1200
EC-1600
7
PNR.752-5600 SW Nut M6
unit: pieces
Cateye ergometer Service Manual
104
EC-3600
EC-3700
EC-C400
EC-C400R
®
CO.,LTD.
2-8-25, Kuwazu, Higashi-ku, Osaka, 546-0041 JAPAN
PHONE: 81-6-6719-7781
FAX: 81-6-6719-2362